JP2009155816A - Wall panel and bathroom unit having this wall panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a wall panel capable of forming joints being effective for improving the design property and achieving satisfactory resistance to chemicals and cleaning capability and to provide a bathroom unit having this wall panel. <P>SOLUTION: This wall panel is constituted by laminating a basic material and a printed pattern layer, a first clear layer, and a second clear layer on the basic material sequentially in this order from below. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a wall panel forming a wall surface of a bathroom and a bathroom unit having the wall panel.

  The bathroom unit is a bathroom that is completed by assembling unitized members so that the construction of the bathroom, which takes days compared to the conventional construction method, can be performed in a short time, and is widely used today. Concrete members that form the bathroom unit include waterproof pans that form floors, wall panels that form wall surfaces, ceiling panels, and bathtubs. In addition, mirrors, counters, shelves, showers, etc. are installed as appropriate. ing.

The wall panel, which is a member forming the bathroom unit, is not only used as a wall, it is necessary to prevent water from leaking out of the bathroom, and further, it has detergent resistance, chemical resistance, etc. It needs to be superior in terms of functionality.
In addition, since bathroom units prefer a space where both mind and body can be relaxed, the design of wall panels is also regarded as important. Specifically, there are patterns that use natural materials such as marble patterns and wood grain as motifs, shapes that are partitioned by joints such as tiles and stones, and high-smooth and high-gloss surfaces that express cleanliness.
As an example of a wall panel with excellent functionality and design, the wall panel's design surface is formed by ink-jet printing, and a transparent clear layer is used on this printed layer to produce surface smoothness, gloss, and depth. There is a thing given.
JP 2007-196435 A

However, although the method of laminating the clear layer on the printing layer by the above-described ink jet printing has depth and smoothness, it does not lead to a design expression in which a step due to joints or the like is given.
As a method for forming a joint pattern, a method is known in which a masking tape is applied in the vertical and horizontal directions corresponding to the joint portion, a paint is sprayed thereon with a paint gun or the like, and the masking tape is peeled off after the paint is dried.
However, this method is not excellent in solvent resistance, chemical resistance and the like because the printed pattern is exposed at the bottom of the joint groove. Further, the joint step concave shape formed by the masking tape has an acute angle, and there is a concern that dirt adheres to the bottom of the groove step and the cleaning property is deteriorated.
Furthermore, when the joint width is narrow and the depth is shallow, the protective coating is applied to the bottom portion of the joint groove step, and the volume of the joint step portion becomes small with respect to the amount of the coating liquid, so that the paint is likely to overflow or protrude. Therefore, it is difficult to apply manually (brush, spray, dispenser). Although it is possible to apply the protective coating to a machine-controlled coating facility, the initial investment is large and the product cost is greatly increased.

  An object of the present invention is to provide a wall panel and a bathroom unit that form joints effective in improving design properties and have good chemical resistance and cleanability.

The present invention relates to the following.
(1) A wall panel in which a printed pattern layer, a first clear layer, and a second clear layer are laminated in this order from the lower layer on the substrate.
(2) The wall panel in which the first clear layer and the second clear layer are formed of the same resin or different resins in the item (1).
(3) In the item 1 or (2), the thickness of the first clear layer and the second clear layer is the same or different.
(4) In any one of items (1) to (3), the first clear layer is divided into a plurality of regions in plan view, and the second clear layer is divided into a plurality of regions. Wall panel covering all of the clear layer.
(5) The wall panel in which the second clear layer is laminated after curing or semi-curing of the first clear layer in any one of items (1) to (4).
(6) A wall panel in which functionality or design is imparted to the first clear layer and the second clear layer in any one of items (1) to (5).

ADVANTAGE OF THE INVENTION According to this invention, while being able to form the joint effective for a design improvement, a chemical-resistant and cleanable thing can be provided.
In addition, since an interface is formed between the first clear layer and the second clear layer, even if a crack occurs on the surface due to an external impact, the expansion of the crack is suppressed by this interface, and the printed pattern It does not reach the layer, and it is easier to repair.
When the first clear layer and the second clear layer are the same resin, the adhesion between the first clear layer and the second clear layer is improved. Therefore, peeling of the interface hardly occurs.
When the first clear layer and the second clear layer are different resins, for example, the first clear layer is a paint having good adhesion to the substrate, and the second clear layer is a functional paint (water repellent). A functional coating film can be formed by using oil repellency, hard coat, etc.
When the first clear layer and the second clear layer have the same thickness, it is possible to save time and effort for adjusting the amount of coating liquid when applying the first and second clear layers.
When the first clear layer and the second clear layer have different thicknesses, the total paint cost can be reduced by using a low-cost paint for the thicker clear layer.
When the first clear layer is divided into a plurality of regions in plan view and the second clear layer covers all of the first clear layers divided into the plurality of regions, By covering a certain printed pattern layer with the second clear layer, the printed pattern layer can be protected. Further, since the second clear layer flows and cures in the joint step concave shape, the corner becomes smooth. Therefore, improvement in cleanability can be expected due to the smooth corners.
In the case where the second clear layer is laminated after the first clear layer is cured or semi-cured, the disappearance of the joint step due to the flow of the first clear layer is prevented.
When functionality or design is imparted to the first clear layer and the second clear layer, for example, by providing water repellency and oil repellency to the second clear layer, the cleanability of joint step portions is excellent. I can do things. Moreover, the hard coat property can be imparted to the second clear layer to improve the durability, or a glittering material can be blended in the first clear layer to impart the design property.

The base material described in the present invention has rigidity as a wall panel, and does not limit the material.
Specifically, a metal plate such as a steel plate, a plastic plate such as urethane, an inorganic plate such as cement, a fiber reinforced plastic (FRP) plate using glass or the like, a wood plate, or the like can be used.
However, when the wall panel is used in a water field, it is preferable to apply a rust-proof plating treatment to the metal plate or use a metal plate having rust-proof performance.
In addition, the base material does not need to be a single plate, and may be formed by laminating a plurality of substrates. When laminating, different materials or the same materials may be combined. good. Most preferred is a resin sheet-coated steel sheet with an ink-receiving layer that has a good nickname for the adsorptivity with the printed pattern ink.

The printed pattern layer described in the present invention is not particularly limited in the printing method such as ink jet printing and screen printing. Also, the ink is not particularly limited, and solvent-based, water-based, UV-based, and the like can be used, and solvent-based ink that makes good adhesion between the ink receiving layer of the substrate and the first clear layer is used. It is preferable to do. The ink color can be appropriately selected from cyan, magenta, yellow, black, white, gray, light cyan, light magenta, light yellow, translucent color, and the like.
The pattern, color, and resolution to be printed are not particularly limited, and a free pattern and color can be printed.

The first and second clear layers described in the present invention are particularly suitable as long as they have translucency (meaning that the printed pattern layer can be seen including colorless and transparent, colored and translucent) after curing. It is not limited, and acrylic resin, urethane resin, polyester resin, epoxy resin, etc. can be used. The method for curing the resin is not particularly limited, such as room temperature curing, thermal effect, UV curing.
The method for applying the first and second clear layers can be performed by brush coating, electrostatic coating, spray coating, roll coater, flow coater, ink jet, screen coating or the like, and is not particularly limited.

The applied film thickness is preferably 25 μm to 100 μm for both the first and second clear layers. If it is 25 μm or less, glossiness and transparency are impaired. On the other hand, if the thickness is extremely thick, the manufacturing cost is greatly affected by the design, so that 100 μm or more is not preferable.
The joint width is not particularly limited, but is preferably about 1.5 mm to 10 mm so that the joint width can be recognized. The joint level difference is preferably 25 μm to 100 μm. If it is 25 μm or less, it becomes too shallow to be recognized as a joint, and the design is not improved. When the thickness is 100 μm or more, dirt easily accumulates in the stepped portion, resulting in poor cleanability.

  The method for separating the first clear layer is not particularly limited, and masking tape, ink jet coating, screen printing, and the like can also be used. As for the masking tape, a single-sided adhesive such as a film or paper is preferable, and the thickness is preferably in the range of 0.1 mm to 1 mm in consideration of workability such as ease of sticking and ease of peeling. Regarding the width, since the width of the masking tape becomes the joint width, a width of 1.5 mm to 10 mm that can recognize the joint is preferable.

  There are water repellency, oil repellency, hard coat property, hydrophilicity, etc. with regard to imparting functionality of the first and second clear layers, and in terms of water repellency and oil repellency, a two-component type of silicone hydrolysis polycondensation reaction curing type of thin film Resin etc. are mentioned. Examples of the hard coat property include a one-component UV curable resin, a nano silica-silane-acrylate copolymer integrated resin, and the like. In the case of hydrophilicity, a two-component aqueous nanosilica-silane-urethane composite cross-linked hybrid resin can be used. Any functional resin may be selected for convenience without particular limitation.

  As for the designability of the first and second clear layers, a pearly tone by adding a glittering material to the resin can be used. With regard to the type and material of the glitter material, titanium dioxide coated glass flakes, pearl pigments, aluminum vapor deposition powder, film vapor deposition cutting powder and the like can be mentioned. These may be selected for convenience as required.

An embodiment of the present invention will be described below with reference to the drawings.
The base layer 1 is a hot-dip galvanized steel sheet having a length of 2000 mm, a width of 1000 mm, and a thickness of 0.5 mm. Were laminated.
On the base material 1, a marble-like printed pattern layer 2 was applied by an ink jet printer using solvent inks of four colors of cyan, magenta, yellow and black. (Figure 1)
After the ink was dried, a masking tape 3 made of a paper single-sided adhesive having a width of 1.8 mm and a thickness of 0.2 mm was attached to a place where a joint step portion was to be provided. (Figure 2)
Thereafter, a paint in which a colorless transparent acrylic urethane paint was blended with 0.1% of a titanium dioxide-coated glass flake (particle diameter 20 μm) luster was applied by spray coating to form the first clear layer 4. (Figure 3)
After coating, the solvent in the paint was volatilized at room temperature for 20 minutes, and then forcedly heated at 80 ° C. for 30 minutes to semi-cure the paint, and the masking tape 3 was peeled off. (Fig. 4)
Thereafter, a silicone hydrolyzed polycondensation reaction cured resin, which is a water and oil repellent performance paint, was applied by spray coating to form a second clear layer 5. (Fig. 5)
After coating, the solvent in the paint was volatilized at room temperature for 20 minutes and heated at 90 ° C. for 60 minutes to completely cure both the first clear layer and the second clear layer.
The completed first clear layer and second clear layer are 25-30 μm thick, the formed joints are 1.8 mm wide, the steps are 25-30 μm, and the corners of the steps are rounded. Met.
As described above, it is possible to create a wall panel that has excellent chemical resistance and cleanability, is easy to repair cracks and scratches to the printed pattern layer, is easy to repair the surface layer, and has water and oil repellency functionality. It was. In addition, it was possible to produce a design that was made by bonding marble with glittering materials and joint steps.

Sectional drawing which gave the printing pattern layer by the inkjet to the base material which is an Example of this invention is shown. FIG. 1 shows a cross-sectional view with a masking tape. FIG. 2 shows a cross-sectional view in which the first clear layer is formed. Sectional drawing which removed the masking tape from FIG. 3 is shown. FIG. 4 shows a cross-sectional view in which the second clear layer is formed.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Base material, 2 ... Printed pattern layer, 3 ... Masking tape, 4 ... 1st clear layer, 5 ... 2nd clear layer.

Claims (6)

The wall panel which laminated | stacked the base material and the printed pattern layer, the 1st clear layer, and the 2nd clear layer in order from the lower layer on this base material. The wall panel according to claim 1, wherein the first clear layer and the second clear layer are formed of the same resin or different resins. The wall panel according to claim 1 or 2, wherein the thicknesses of the first clear layer and the second clear layer are the same or different. The first clear layer according to any one of claims 1 to 3, wherein the first clear layer is divided into a plurality of regions in plan view, and the second clear layer includes all of the first clear layers divided into the plurality of regions. Covering wall panels. The wall panel according to any one of claims 1 to 4, wherein the second clear layer is laminated after the first clear layer is cured or semi-cured. 6. The wall panel according to claim 1, wherein functionality or design is imparted to the first clear layer and the second clear layer.

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