Title of Invention

" A WALL REPAIRING MEHTOD"

Abstract A wall-repairing method, which comprises heat melting by use of a heating unit a solid repairing material mainly containing a thermoplastic resin and having a melting temperature in the range of 30 to 150°C and preferably in a line-shaped material having a sectional area in the range of 0,05 to 100 mm2 to form a heat melted repairing material, followed by pushing and pressing the heat melted repairing material into a concave space formed in the wall and to be repaired to fill the concave space; and a wall-reforming method which comprises repairing the wall by the above wall-repairing methods, followed by coating a coating composition all over the wall including the repaired area for finishing.
Full Text SPECIFICATION
Title of the Invention:
Wall-Repairing Method and Wall-Reforming Method
Background Art:
Field of the Invention:
The present invention relates to a wall-repairing
method, and a method of reforming the wall as a whole
including a repaired area.
Description of Background Art:
A wall used for an interior decoration in an
architectural structure is usually prepared by closely
cementing a plurality of plate materials such as a
plasterboard and the like.
Japanese Patent Application Laid-open No. 82071/96
discloses a finishing method or a reforming method of the
interior decoration wall composed of above plate materials,
which method comprises filling a putty composition into a concave space such as a concaye space formed between plate materials closely cemented together, a concave space formed in the surface of the plate material by loss and the like, followed by coating a coating composition or applying a plurality of cloth marerials all over the interior decoration
wall (Reference 1}.
Generally, the interior decoration cloth used in the architectural structure is such that a plurality of cloth materials having a predetermined size are closely cladded
together on the surface of a wall composed of the plate materials, and that an open space may be formed between cloth materials closely cladded together. On the other hand, the cloth material itself may have an open space due to loss. Recently, an interior decoration cloth-reforming method comprising coating a coating composition onto the interior decoration cloth is proposed, wherein a putty composition containing a synthetic resin emulsion as a resin component is filled into the concave space between cloth materials closely cladded together or the concave space due to loss in the cloth material, followed by coating a coating composition.
However, the above repairing method by use of the putty composition may result in that a formed putty layer may become thin after application of the putty composition, and may result an unsatisfactory finished appearance. Coating of a coating composition onto the putty layer may result absorption of the resin component of the coating composition into the putty layer, and may result flashing, color drift and cracks in a coating film due to failure in film formation on drying. Further, the hard putty layer formed from the putty composition may not be able to follow conditions of the substrate material, resulting in developing cracks on cemented portion of the plasterboard with time and the like, and making coa~ finishing difficult. Summary of the Invention:
It is an object of the present invention to provide a wall-repairing and coating method capable of simply repairing
and leaving no marks on the repaired area.
The present inventors made intensive studies for the purpose of solving the above problems to find out that a method of heat melting by use of a heating unit a solid repairing material mainly containing a thermoplastic resin and having a specified melting temperature to form a heat melted repairing material, followed by pushing and pressing the heat melted repairing material into a concave space formed in the wall and to be repaired to fill the concave space makes it possible to solve the above problems, resulting in completing the present invention.
That is, the present invention relates to
1. A wall-repairing method, which comprises heat melting by use of a heating unit a solid repairing material mainly containing a thermoplastic resin and having a melting temperature in the range of 30 to 150°C to form a heat melted repairing material, followed by pushing and pressing the heat melted repairing material into a concave space formed in the wall and to be repaired to fill the concave space,
2. A wall-repairing method as described in paragraph 1, wherein the concave space is a concave space formed between wall materials,
3. A wall-repairing method as described in paragraph 1, wherein the concave space is a concave space formed in the surface of the wall due to loss,
4. A wall-repairing method as described in paragraph l,
wherein the wall consists of a plate material and a cloth material cladded on the plate material,
5. A wall-repairing method as described in paragraph i, wherein the wall consists of a plate material and a cloth material cladded on the plate material, and a concave space of the cloth material is a concave space formed between cladded cloth materials adjacent to each other,
6. A wall-repairing method as described in any one of paragraphs 1 to 5, wherein the repairing material is a line-shaped material having a sectional area in the range of 0.05 to 100 mm2,
7. A wall-repairing method as described in any one of paragraphs 1 to 6, wherein the repairing material contains a pigment in an amount of 5 to 80% as a pigment volume concentration,

8. A repairing material used in any one of wall-repairing methods as described in paragraphs 1 to 7,
9. A wall-reforming method which comprises repairing the wall by any one of wall-repairing methods as described in paragraphs 1 to 7, followed by coating a coating composition all over the wall including the repaired area for finishing.
Brief Description of the Drawings:
Fig- 1 is a plan view and side view for explaining an example of a test material used in evaluation tests.
Fig. 2 is a schematic view for explaining an example of a heating unit used in the present invention. In Fig. 2, 1
represents a brass plate, 2 represents a heating element, and 3 represents a grip.
The present invention provides the following particular effects.
The repairing method of the present invention makes it possible to simply apply in a short period of time, and to start a finishing step such as coating step or cloth-cladding step immediately after the concave space-repairing step. The use of the repairing material containing a large amount of thermoplastic resin component makes it possible to form a repaired surface having the same gloss as that of cloth and leaving no marks, resulting in being suitable for repair of a cloth-cladded wall. Coating of a coating composition all over the wall including the concave space-repaired area results in that an amount of the resin component of the coating composition to be absorbed into the concave space-repaired area may be almost the same that to be absorbed into the cloth of the cloth-cladded wall, in that the concave space-repaired area leaves no marks, and in that a whole surface of the coated wall may show good finished appearance. Detailed Description of the Invention:
The wall used in the wall-repairing method of the present invention may include,, for example, a plate material used in an architectural interior decoration, a wall consisting of the plate material and a coating film coated on the plate material, a wall consisting of the plate material and a cloth material cladded on the plate material, and the
like. A concave space in the wall may include, for example, a concave space formed in the wall due to loss and a concave space formed between cemented wall materials adjacent to each other. The concave space formed between cemented wall materials adjacent to each other may include, for example, a concave space between cemented plate materials adjacent to each other and a concave space between cladded cloth materials adjacent to each other. The concave space between cladded cloth materials adjacent to each other may be widened on application or with time, for example, at an interval by 0.1 to 2.0 mm.
The repairing material used in the repairing method of the present invention mainly contains a thermoplastic resin component and a little amount of pigment component, and the resulting repaired layer has almost the same gloss and appearance as the vinyl cloth component, resulting in that the repairing method of the present invention is suitable for repairing the vinyl cloth component.
The repairing material is preferably solid so as to melt by heating, specifically has a melting temperature in the range of 30 to 150°C, preferably 50 to 140°.C. When the melting temperature is less than 30°C, not only stickiness may remain after application, but also sagging may take place at a high room temperature. On the other hand, when higher than 150°C, a large amount of heat source may be needed, and application efficiency may be reduced.
The thermoplastic resin as the main component may
include, for example, polyethylene resin, polypropylene resin, chlorinated polypropylene resin, polyurethane resin, ethylene-vinyl acetate copolymer, polyimide resin and the like. In addition to the thermoplastic resin, the repairing material may optionally contain waxes, fillers, additives, pigments and the like.
The pigment may be used for the purpose of improving abrasion properties in an amount of 5 to 80%, preferably 20 to 60%, as a pigment volume concentration.
In the present specification, the pigment volume concentration means a volume percentage of a total pigment solid content relative to a total solid content of resin and pigment in a coating composition. A specific gravity of pigment in calculating a volume of pigment is cited from Paint Material Handbook, 6th Edition printed by Japan Paint Manufacturers Association, and a specific gravity of resin solid content is approximately 1 (one).
The pigment preferably mixed in the repairing material may include, for example, an extender pigment such as talc, mica, barium sulfate, kaolin, calcium carbonate, clay, silica, quartz, glass and the like, a color pigment such as titanium white, red iron oxide, carbon black, iron black and the like, and may also include glass balloon, plastic balloon and the like. These may be used alone or in combination.
The shape of the repairing material may arbitrarily be selected depending on a shape of a repairing area, but may include, for example, a flat shape such as circle, square,
polygon and the like; a line-like shape such as stick, string, yarn and the like; L letter-like shape, measure-like shape and the like. The shape of the repairing material once formed may be changed during operation. In the case where the repairing area is a concave space between cloth materials cladded together or a concave space between wall materials cemented together, the area may a slender concave shape ranging from floor to ceiling, and a line-shaped repairing material having a sectional area of 0.05 mm2 to 100 mm2, preferably 0.1 to 30 mm2 may be suitable from the standpoint of workability. A sectional area more than 100 mm2 may need a large amount of heat source for melting the repairing material.
The shape of sectional area in the line-shaped repairing material may not particularly be limited, but may include, for example, polygon, circle and the like. Reeling up of the line-shaped repairing material may enhance an application efficiency, and further housing the reeled up repairing material in a holder having a cutter makes it possible to use a necessary section only of the repairing material to be highly convenient.
The heating unit to melt the repairing material may include usual heating appliances, for example, an iron, dryer, trowel, infrared light heater, roller having a heating element and the like. These may be arbitrarily selected depending on conditions of the repairing area, and the trowel and roller having a heating element are preferable in that
operation can be carried out efficiently.
In the present invention, on heat melting the repairing material, the above heating appliances may be used as they are, and preferably a release material may be applied between heating unit and repairing material in preventing the melt repairing material from being adhered to the heating unit. Specific examples of applying the release material may include, for example, a method of treating and processing an area contacting with the repairing material of the heating unit: with a release material mainly containing fluorocarbon resin, silicone resin, fluorocarbon resin•silicone resin and the like; a method of mounting a metal sheet, the surface of which is treated and processed with the release material, on an edge of the heating unit, a method of fitting a release sheet prepared by applying the release material to a metal film, paper and the like between the repairing material and heating unit to performing repairing procedure, and the like.
In the present invention, filling of the melted repairing material into a concave space may be followed by cooling as it is to cure the repairing material, and optionally removing or abrading a projected portion of the repairing material.
The present invention further provides a wall-reforming method which comprises repairing the wall according to the above repairing method, followed by coating a coating composition all over the surface of the wall including a repaired area for finishing.
A topcoat coating composition used in the method of the present invention may include the water based or organic solvent based coating composition known in the art without particular limitations, for example, ones containing mainly a resin such as acrylic resin, acryl • urethane resin, polyurethane resin, fluorocarbon resin, silicone - acryl resin and the like, and further containing pigments, additives for use in the coating composition and the like.
The pigment used in the topcoat coating composition may include, for example, a color pigment such as titanium white and the like; an extender pigment such as calcium carbonate, hydrous magnesium silicate, talc, clay, baryta and the like; optionally an adsorbent such as active alumina, diatomaceous earth, stratified clay and the like, and anti-corrosive pigment.
The additive for use in the coating composition may include, for example, pigment dispersant, surface active agent, dispersant, anti-foaming agent, thickening agent, film-forming assistant, antiseptic agent, mildew-proofing agent, anti-freezing agent, pH-controlling agent, flush rust inhibitor, aldehyde uptake/adsorbing agent, and the like.
The above topcoat coating compositions may arbitrarily oe selected depending on uses, in that adhesion properties to the repaired area are good, and that the resulting coating film shows non-stickiness.
In the present invention, the glass transition temperature Tg (absolute temperature) is a value calculated according to the following equation:
(Equation Removed)
where Wl, W2 Wn respectively represent % by weight, i.e.
amount by-weight of respective monomer/total amount by weight
of monomers x 100(%), and T1, T2 Tn respectively
represent a glass transition temperature (absolute temperature) of the homopolymer of respective monomers. The glass transition temperature of the homopolymer of respective monomers is a value cited from Polymer Handbook (Second Edition, compiled by Brandrup• E.H. Immergut). The glass transition temperature of the homopolymer of monomers not described in the above reference is a value obtained by measuring a glass transition temperature of a synthesized homopolymer by differential thermal analysis.
Coating of the topcoat coating composition may be carried out by a coating method such as spraying, roller coating, brushing and the like preferably at a coating weight in the range of 80 to 300 g/m2. Prior to coating the topcoat coating composition, a sealer may optionally be coated for the purpose of improving adhesion properties to the surface of the wall material and repaired area. Example Preparation of Repairing Material

AUROREN 150S (trade name, marketed by Nippon Paper Chemicals Co., Ltd., polypropylene resin based thermoplastic resin, melting point 105 ~ 135°C) was charged into various kinds of molds respectively, followed by heat melting, cooling, taking out from the mold to obtain solid repairing materials (A) to (E) having shapes as shown in Table 1 respectively. The repairing material (F) is such that a stainless steel vessel having a hole of 0.5 mm in diameter was heated, followed by drawing out the above resin through the hole, forming a string, wrapping onto a carrying-cellophane tape holder with a cutter to form a reel. The repairing material (G) was prepared in the same manner as in the preparation of repairing material (D) except that a polypropylene based resin powder having a melting point of 160°C was used. The repairing material (H) was prepared in the same manner as in repairing material (A) except that a talc as the pigment was mixed in an amount of 40% of a pigment volume concentration.
Table 1

(Table Removed)
Examples 1-7 and Comparative Examples 1-2 Preparation of Test Panel
A vinyl resin cloth having an adhesive on the back side was cladded onto a 450 * 300 x 9.5 mm plasterboard, and the vinyl resin cloth-cladded plasterboard was cut to obtain a vinyl resin cloth-cladded plasterboard forming a cut portion or a concave space (Fig. 1) having a width and depth as shown in Table 2 (test panel). In Table 2, a depth of 0 (zero) mm means that the vinyl resin cloth only is cut, and a concave space between cladded vinyl resin cloth. A depth other ~han 0 (zero) mm shows a concave space due to loss.
Respective repairing materials shown in Table 2 were heat melted by use of an iron trowel shown in Fig. 2, followed by trowelling the heat melted repairing material to fill the cut concave space with respective repairing materials, abrading the repaired area to level between the repaired area and non-repaired area, coating Viny-Deluxe 300 (trade name, marketed by Kansai Paint Co., Ltd., acrylic resin based matte water based coating composition, resin Tg 10°C, pigment volume concentration 55%) all over the test panel including the repaired area by use of a wool roller to be a coating weight of 120 g/m2, and 2 hours after repeating the above coating step.
In Fig. 2, an iron trowel is composed of a triangular brass plate 1 having the base of 50 mm, a cylindrical heating element 2 and a grip 3, wherein an angular portion of the brass plate 1 is connected with an edge of the heating
element 2, the brass plate 1 has a thickness of 3 mm and is
treated with a fluorocarbon resin all over the surface, and
the iron trowel can be connected with a 100V-20W electric
source.
Performance Evaluation
Workability and finish properties were evaluated by use of the test panel as follows. Results are shown in Table 2. (*1) Repair Workability
The repair workability was evaluated by a time required for filling the cut concave space with the repairing material as follows.
©: working completed in 30 seconds or less. O: working completed in 30 seconds to one minute-A: working completed in 1 to 3 minutes. X; working completed in 3 minutes and more. (*2) Unevenness after topcoat coating
One day after the preparation of the test panel, unevenness between repaired area and non-repaired area was visually evaluated as follows. ®: almost no unevenness observed. O: some unevenness observed from an oblique direction, but
almost no unevenness observed as a whole. A: unevenness observed as a whole, but tolerable, x: serious unevenness observed, and redoing is necessary. (*3) Flashing after topcoat coating
One day after the preparation of the test panel, flashing between repaired area and non-repaired area was
visually evaluated as follows.
(O): almost no flashing observed.
O: some flashing from an oblique direction, but almost no
flashing observed as a whole. : flashing observed as a whole, but tolerable. X: serious flashing observed, and redoing is necessary.
Table 2

(Table Removed)
(Note 1) Putty composition: a general purpose thin-wall synthetic resin emulsion putty composition in accordance with JIS K 5669.
Industrial Applicability:
The present invention is suitably applicable to repairing and reforming of an architectural interior decoration wall.







We claim:
1. A wall repairing method, which comprises heat melting by use of a heating unit a solid repairing material mainly containing thermoplastic resin and having a melting temperature in the range of 30 to 150°C to form a heat melted repairing material, followed by pushing and pressing the heat melted repairing material into a concave space followed in the wall and to be repaired to fill the concave space.
2. A wall repairing method as claimed in claim 1, wherein the wall consists of a plate material and a cloth material cladded on the plate material, and a concave space of the cloth material is a concave space formed between cladded cloth materials adjacent to each other.
3. A wall repairing method as claimed in any one of the claims 1 to 2, wherein the repairing material is a line shaped material having a sectional area in the range of 0.05 to 100mm2.
4. A wall repairing method as claimed in any one of the claims 1 to 3, wherein the repairing material preferably contains a pigment in an amount of 5 to 80% as a pigment volume concentration.
5. A repairing material used in any one of wall- repairing methods as claimed in claims 1 to 4.
6. A wall repairing method substantially as herein described with referenced to the foregoing examples.
7. A repairing material used substantially as herein described with referenced to the foregoing examples.


Documents:

1081-del-2004-abstract.pdf

1081-del-2004-claims.pdf

1081-del-2004-complete specification (as files).pdf

1081-del-2004-complete specification (granted).pdf

1081-del-2004-correspondence-others.pdf

1081-del-2004-correspondence-po.pdf

1081-del-2004-description (complete).pdf

1081-del-2004-drawings.pdf

1081-del-2004-form-1.pdf

1081-del-2004-form-19.pdf

1081-del-2004-form-2.pdf

1081-del-2004-form-3.pdf

1081-del-2004-form-5.pdf

1081-del-2004-gpa.pdf


Patent Number 244122
Indian Patent Application Number 1081/DEL/2004
PG Journal Number 47/2010
Publication Date 19-Nov-2010
Grant Date 18-Nov-2010
Date of Filing 09-Jun-2004
Name of Patentee KANSAI PAINT CO., LTD.
Applicant Address 33-1, KANZAKI-CHO, AMAGASAKI-SHI, HYOGO-KEN, 661-0964, JAPAN
Inventors:
# Inventor's Name Inventor's Address
1 SUGISHIMA MASAMI C.O KANSAI PAINT CO., LTD. 17-1, HIGASHIYAWATA 4-CHOME, HIRATSUKA-SHI, KANAGAWA-KEN, 254-0016,JAPAN.
2 SAIKAWA KEIICHIRO C.O KANSAI PAINT CO., LTD. 17-1, HIGASHIYAWATA 4-CHOME, HIRATSUKA-SHI, KANAGAWA-KEN, 254-0016,JAPAN.
3 HIRAYAMA TOHRU C.O KANSAI PAINT CO., LTD. 17-1, HIGASHIYAWATA 4-CHOME, HIRATSUKA-SHI, KANAGAWA-KEN, 254-0016,JAPAN.
PCT International Classification Number B05D 5/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-164480 2003-06-10 Japan
2 2004-166790 2004-06-04 Japan