JP2004150177A - Bathroom floor material and method of producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bathroom floor material which enhances the adhesion of a hydrophilic paint to a base material and the durability of the hydrophilic paint, and fully exhibits hydrophilic property by virtue of the hydrophilic paint. <P>SOLUTION: The bathroom floor material 10 is formed of the predetermined base material 11, a primer layer 12 formed by applying a primer paint to the base material 11, and a top coat layer 13 formed by applying the hydrophilic paint to the primer layer 12. Herein the primer paint has a hydrophilic material such as hydrophilic silica and/or a hydrophilic agent added thereto. The hydrophilic agent functions to produce a hydrophilic group such as Si-OH group on a surface of the paint, to thereby form the primer paint into a hydrophilic structure. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a bathroom flooring material and a method for producing the same, and more particularly to a bathroom flooring material capable of improving the adhesion and durability of a hydrophilic paint to a substrate and imparting high hydrophilicity, and a bathroom flooring material therefor. It relates to a manufacturing method.
[0002]
[Prior art]
As a bathroom floor material, a material having a property of drying hot water left on the surface after bathing as quickly as possible (easy drying property) is required. Therefore, in the case of a floor material for a unit bath formed of a resin material, if the surface of the base material is coated with a predetermined hydrophilic paint (see, for example, Patent Document 1), the surface becomes hydrophilic and the drying property is improved. It is known to improve. At this time, in order to increase the adhesion and durability of the paint to the painted surface, a primer paint is applied or sprayed on the painted surface before the painting process using the hydrophilic paint (see Patent Documents 1 and 2).
[0003]
[Patent Document 1]
Japanese Patent Application Laid-Open No. 2000-301054 [Patent Document 2]
Japanese Patent Application Laid-Open No. 2000-308847
[Problems to be solved by the invention]
However, as described above, when a primer coating material is used, there is a disadvantage that the hydrophilicity of the hydrophilic coating material cannot be sufficiently exerted, and a favorable floor material cannot be obtained. It is presumed that this is because the hydrophilic additive present in the hydrophilic paint settles in the primer paint and hardly appears on the surface of the coating film of the hydrophilic paint.
Here, before the coating with the hydrophilic paint, if the primer paint is once heated and cured, the hydrophilicity of the flooring material is somewhat better than in the above-mentioned case, but the good easy drying property is obtained. Is not enough. In addition, in this case, the step of heating and curing the primer coating and the hydrophilic coating must be performed twice, which leads to an increase in manufacturing cost due to an increase in the number of steps.
Further, if the hydrophilic paint is applied without using the primer paint, the hydrophilicity of the flooring material is improved, but there is a disadvantage that the adhesion and durability of the hydrophilic paint to the base material are deteriorated. This inconvenience is particularly remarkable when the base material is formed of FRP (fiber reinforced plastic) such as SMC (sheet molding compound) due to various release agents and use environment.
[0005]
[Object of the invention]
The present invention has been devised in view of such inconvenience, and the object is to sufficiently exhibit the hydrophilicity of the hydrophilic paint while improving the adhesion and durability of the hydrophilic paint to the substrate. An object of the present invention is to provide a bathroom floor material that can be made to work and a method for manufacturing the same.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a predetermined base material, a primer layer formed by coating the base material with a primer coating, and coating the primer layer with a hydrophilic coating. In a bathroom flooring material with a top coat layer formed of
A configuration is adopted in which a hydrophilic substance is added to the primer coating. According to such a configuration, since the hydrophilic substance is added to the primer coating, it is considered that the hydrophilic substance can suppress the migration of the hydrophilic additive in the hydrophilic coating into the primer layer. As a result, the hydrophilicity of the hydrophilic paint can be sufficiently exhibited. Moreover, since the primer coating is used, the adhesion and durability of the hydrophilic coating to the substrate can be improved.
[0007]
It is preferable that the hydrophilic substance is hydrophilic silica, and it is preferable that the hydrophilic substance is added in an amount of 0.1% by weight to 10% by weight based on the main agent of the primer coating material. If the amount of the hydrophilic silica is less than 0.1% by weight, it is difficult to impart the expected hydrophilicity to the flooring material. On the other hand, if the amount of the hydrophilic silica exceeds 10% by weight, the viscosity of the primer coating material is reduced. If it is too high, atomization coating using the primer coating cannot be performed.
[0008]
Here, it is preferable that the hydrophilic silica has not been subjected to a coupling treatment. Thereby, the influence of the water repellent component coupled to the hydrophilic silica is reduced, and the hydrophilicity of the floor material can be further increased.
[0009]
Preferably, the hydrophilic silica has an average particle diameter of 0.1 μm to 20 μm. If the average particle size of the hydrophilic silica is less than 0.1 μm, the viscosity of the primer coating becomes too high, and atomization coating using the primer coating cannot be performed. On the other hand, when the average particle size of the hydrophilic silica exceeds 20 μm, irregularities are likely to be formed on the painted surface, and it is difficult to form a flat painted surface with good appearance. Here, it is more preferable that the average particle size of the hydrophilic silica is 2 μm to 10 μm.
[0010]
Further, it is preferable that the hydrophilic silica has an average secondary particle diameter of 1 μm to 20 μm. If the average secondary particle diameter of the hydrophilic silica is less than 1 μm, the viscosity of the primer coating becomes too high, and atomization coating using the primer coating cannot be performed. On the other hand, when the average secondary particle diameter of the hydrophilic silica exceeds 20 μm, irregularities are likely to be formed on the painted surface, and it is difficult to form a flat painted surface with good appearance. Here, it is more preferable that the average secondary particle diameter of the hydrophilic silica is 2 μm to 10 μm.
[0011]
Further, the primer layer may be configured so as not to contain an additive component having water repellency. In this case, the water repellency of the primer paint is reduced, and the hydrophilicity of the floor material can be further improved. Here, examples of the water-repellent additive include a wetting and dispersing agent and a leveling agent.
[0012]
Further, it is preferable to form irregularities on the portion of the base material coated with the primer paint, and according to this, the hydrophilicity of the floor material and the adhesion of the hydrophilic paint can be further enhanced.
[0013]
The production method according to the present invention includes an undercoating step of coating a predetermined base material with a primer coating to which a hydrophilic substance has been added, an overcoating step of coating the primer coating with a hydrophilic coating from above, and the primer And a curing step of heating and curing the paint and the hydrophilic paint. According to such a method, the above-described object can be achieved, and in addition, the primer coating material and the hydrophilic coating material can be cured in one curing step, and the floor material can be manufactured more quickly.
[0014]
Here, before the undercoating step, by performing a polishing step of polishing the surface to be coated of the base material with a predetermined polishing member or abrasive, a method of forming irregularities in advance in the coating portion is adopted. You can also. According to such a method, the hydrophilicity of the floor material and the adhesion of the hydrophilic paint can be further enhanced.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
As shown in FIG. 1, a bathroom flooring 10 according to the present invention includes a resinous base material 11, a primer layer 12 formed by applying a primer paint to the base material 11, The basic configuration includes a top coat layer 13 formed by applying a hydrophilic paint to the primer layer 12.
[0016]
The substrate 11 is not particularly limited, but is formed of FRP (fiber reinforced plastic) such as SMC.
[0017]
The primer paint has a component composition obtained by adding at least a hydrophilic substance to the components of a known primer paint. The hydrophilic substance is added to the main agent of the primer paint, and hydrophilic materials such as hydrophilic silica and alumina, and a hydrophilic structure such as a hydrophilic group such as a Si-OH group appear on the painted surface. Means a hydrophilic agent. These hydrophilic materials and hydrophilizing agents may be added both, or either one of them may be added.
[0018]
In this specification, the term "hydrophilic _{group", -OH, -O -, - NHCO} -, - CONH 2 -, - COOH, -SO 3 H, -OSO 3 H, -OPO (OH) 2 , _-NH 2, _-NH -, - used as a concept that collectively NR ₂ or the like.
[0019]
The hydrophilic paint means a paint capable of forming a coating film having a static contact angle with water of 50 degrees or less, an alkali silicate-containing inorganic paint, a metal alkoxide-containing inorganic paint, an organic-inorganic composite paint, and a surface. Examples include hydrophilic coatings. Here, the organic-inorganic composite coating is a reaction between an organic component such as acryl, urethane, polyester, and epoxy and an inorganic component such as silicate containing silicon or the like as a main component. It is a coating compounded with an alkoxysilane having a group (silane coupling agent) or the like. Further, the surface hydrophilizing paint is a paint having a hydrophilic structure by adding a hydrophilic agent having a hydrophilic group to the paint to expose a hydrophilic group such as a Si-OH group on the surface.
[0020]
The bathroom flooring 10 is manufactured through the following steps.
That is, after the base material 11 is molded, a pretreatment step is performed in which the surface 11A to be a painted portion of the base material 11 is degreased to remove dust and the like. Then, an undercoating step of applying or spraying a primer paint on the surface 11A is performed. Thereafter, an overcoating step of applying or spraying a hydrophilic paint on the primer paint is performed, and the primer paint and the hydrophilic paint are left (set) for a certain period of time. After a curing step of heating and curing the primer paint and the hydrophilic paint is performed, a bathroom flooring 10 is completed through a product cooling step. Before the undercoating step, the surface 11A is polished with a polishing member such as sandpaper or a nonwoven fabric made of abrasive-containing nylon, or a polishing agent to form irregularities or a rough surface on the surface 11A in advance. A step may be performed.
[0021]
In the present specification, the “average particle size” is defined as di of a particle diameter, n1 particles of a diameter d1 in a unit weight of powder, n2 particles of a diameter d2,. When ni particles exist, the arithmetic average diameter (Σdi · ni / Σni) is defined as the average particle diameter.
Here, in the case of particles that are not perfectly spherical, as shown in FIG. 2, the longest diameter (dimension in the long direction) when the particles are viewed in a plan view is L, and the dimension in the direction perpendicular to this is B, Assuming that the plane area of the particles is F and the volume per particle is V, each particle diameter Dp is obtained by any of the following equations (1) to (4).
Dp = B (1)
Dp = √ (4F / π) (equivalent circular diameter, diameter of Heywood) (2)
Dp = V ^1/3 (diameter of Andreasen) (3)
Dp = (6V / π) ^1/3 (equivalent spherical diameter or equivalent diameter) (4)
[0022]
In addition, the “average secondary particle diameter” refers to the above formulas (1) to (4) when particles having an average particle diameter are aggregated by physical or chemical action to form secondary particles. ) Means the particle size determined by the method.
[0023]
【Example】
Hereinafter, examples of the present invention will be described together with comparative examples.
[0024]
[Example 1]
First, an SMC (sheet molding compound) containing various components in the proportions shown in FIG. 3 was molded using a molding die having a surface temperature of 145 ° C. and a back surface temperature of 130 ° C. under a molding pressure of 15000 kN and a keep time of 420 seconds. The substrate 11 for the system bus was formed by the above.
Next, after the substrate 11 was degreased with isopropyl alcohol, air dust was removed, and then a primer layer 12 was provided on the surface 11A of the substrate 11 using a primer paint. At this time, the thickness of the coating film was about 20 μm. As the primer coating, 80 parts of a main component containing acrylic polyol as a main component, 20 parts of a curing agent containing hexamethylene diisocyanate as a main component, 60 parts of a mixed thinner such as toluene and xylene are blended, and further various additives are added. Paints added as appropriate were used. Acrylic beads having an average particle size of 20 μm, hydrophilic silica particles having an average particle size of 5 μm, and a silicon-based hydrophilizing agent (surfactant) were added to the main agent. Here, the addition ratio of the acrylic beads and the silicon-based hydrophilizing agent was 5% by weight with respect to the main agent, and the addition ratio of the hydrophilic silica particles was 0.1% by weight with respect to the main agent.
Next, a top coat layer 13 was provided from above the primer layer 12 using a hydrophilic paint. At this time, the thickness of the coating film was about 30 μm. The hydrophilic paint used had the same basic components as the primer paint except that the average particle size of the hydrophilic silica particles was 2 μm to 10 μm and the addition ratio was 5% by weight.
Then, after leaving it to stand at about 30 ° C. for about 10 minutes, it was placed in a drying oven at 100 ° C. for 30 minutes to cure the primer paint and the hydrophilic paint, and then cooled to obtain the bathroom flooring 10.
[0025]
[Examples 2 to 4]
As shown in FIG. 4, the addition ratio of the hydrophilic silica particles in the primer coating was changed from that of Example 1. That is, in Example 2, hydrophilic silica particles were added at a ratio of 10% by weight with respect to the main agent, and in Example 3, similarly, 0.05% by weight was added with respect to the main agent. Was similarly added at a rate of 12% by weight with respect to the main ingredient.
[0026]
[Examples 5 to 8]
In comparison with Example 2, the average particle size of the hydrophilic silica particles of the primer coating was changed. That is, in Example 5, the average particle size of the hydrophilic silica particles was 0.05 μm, and in Example 6, the average particle size of the hydrophilic silica particles was 0.1 μm. In Example 7, the average particle size of the hydrophilic silica particles was 30 μm, and in Example 8, the average particle size of the hydrophilic silica particles was 20 μm.
[0027]
[Example 9]
As compared with Example 2, as the hydrophilic silica particles contained in the primer coating material, those not subjected to the coupling treatment were used.
[0028]
[Example 10]
In contrast to Example 2, a primer paint containing no water repellent additive component was used.
[0029]
[Example 11]
Before coating with the primer paint, the surface 11A of the base material 11 was polished with sandpaper # 320, and other conditions were substantially the same as those in Example 10.
[0030]
[Example 12]
The curing step was performed twice for Example 1. That is, after the primer coating was left and cured under the same conditions as in Example 1, the coating with the hydrophilic coating was performed, and the hydrophilic coating was left under the same conditions as in Example 1 and cured. .
[0031]
[Comparative Example 1]
In contrast to Example 1, a hydrophilic paint was directly sprayed on the substrate 11 without using a primer paint.
[0032]
[Comparative Example 2]
As compared with Example 1, a known primer coating material to which no hydrophilic substance (silica particles, hydrophilizing agent) was added was used.
[0033]
[Comparative Example 3]
For Comparative Example 2, the curing step was performed twice. That is, as in Example 12, heat curing of the primer paint and heat curing of the hydrophilic paint were separately performed.
[0034]
An experiment for confirming hydrophilicity and adhesion (durability) was performed on each flooring material 10 obtained as described above.
[0035]
Here, in the experiment on the hydrophilicity, the hydrophilicity was evaluated in three steps using the static contact angle with water in the state immediately after the floor material 10 was rinsed with water as a parameter. That is, “「 ”represents a very good evaluation in which the static contact angle with water is less than 20 degrees, and“ ○ ”represents a good evaluation in which the static contact angle with water is 20 degrees or more and 40 degrees or less. Represents “X” indicates that the static contact angle with water exceeds 40 degrees, and the expected hydrophilicity cannot be obtained.
[0036]
In addition, as an experiment on adhesion (durability), after immersion in warm water at 90 ° C. for a predetermined time, a grid test was performed. “◎” indicates that peeling did not occur for 300 hours or more, “○” indicates that peeling occurred for 50 hours or more and less than 300 hours, and “×” indicates that peeling occurred for less than 50 hours. This indicates that peeling has occurred. If no peeling occurs in this test for 50 hours or more, it is considered that there is no problem in practical performance as a bathroom floor material.
[0037]
【The invention's effect】
As is clear from the above experiments, according to the present invention, it is possible to sufficiently exert the hydrophilicity of the hydrophilic paint while improving the adhesion and durability of the hydrophilic paint.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view showing a layer structure of a bathroom floor material according to the present invention.
FIG. 2 is a conceptual diagram for explaining an average particle size.
FIG. 3 is a component table of a base material in Example 1.
FIG. 4 is a table showing experimental conditions and experimental results.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Bathroom flooring material, 11 ... Base material, 11A ... Surface, 12 ... Primer layer, 13 ... Top coat layer

Claims (9)

A predetermined base material, comprising a primer layer formed by coating the base material with a primer coating, and a top coat layer formed by coating the primer layer with a hydrophilic coating. In bathroom flooring,
A bathroom flooring material, wherein a hydrophilic substance is added to the primer coating. The bathroom flooring material according to claim 1, wherein the hydrophilic substance is hydrophilic silica, and is added in an amount of 0.1% by weight to 10% by weight based on a main component of the primer coating material. The bathroom flooring according to claim 2, wherein the hydrophilic silica is not subjected to a coupling treatment. The bathroom flooring according to claim 2 or 3, wherein the hydrophilic silica has an average particle size of 0.1 µm to 20 µm. The floor material for a bathroom according to claim 2, wherein the hydrophilic silica has an average secondary particle diameter of 1 µm to 20 µm. The floor material for a bathroom according to any one of claims 1 to 5, wherein the primer layer does not contain an additive component having water repellency. The bathroom flooring material according to any one of claims 1 to 6, wherein irregularities are formed in a portion of the substrate coated with the primer paint. An undercoating step of coating a predetermined base material with a primer coating to which a hydrophilic substance has been added, an overcoating step of coating with a hydrophilic coating over the primer coating, and heating the primer coating and the hydrophilic coating. And a curing step of performing curing in order. 9. The method according to claim 8, further comprising: performing a polishing step of polishing a surface of the base material to be coated with a predetermined polishing member or an abrasive before the undercoating step, thereby forming irregularities in the coated portion in advance. A method for producing a bathroom floor material as described above.

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