JP2017227095A - Producing method of bath room wall material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a producing method of bath room wall material, which may prevent generation of crinkle on a surface material film and entering of air into a space between a metal plate and the surface material film when the metal plate and the surface material film are jointed with hot melt adhesive agent.SOLUTION: The method includes the following steps (A), (B): (A) a step where a flexible surface material film 2 on which hot melt adhesive agent layer 4 is provided on one surface is supplied to a metal plate 1 to be transported, the metal plate and the surface material film are sandwiched from both outsides by a pair of first heat rolls 12a, 12b in a manner where hot melt adhesive agent layer contacts to a plate surface of the metal plate, and the hot melt adhesive agent layer is softened; and (B) the metal plate and the surface material film are sandwiched from both outsides by a pair of second heat rolls 13a, 13b at downstream of the first heat rolls in transporting direction of the metal plate so that the hot melt adhesive agent layer is melted, and then it is cooled so that the metal plate and the surface material film are jointed.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a bathroom wall material.

  Conventionally, as a wall material for a bathroom used for a unit bath or a system bath, a metal plate is used as a main body, and a resin surface material film is bonded to the surface of the metal plate on the bathroom side (for example, a patent) References 1 and 2).

JP 2010-031531 A JP 2009-108505 A

  This bathroom wall material is obtained by bonding a metal plate and a surface material film with an adhesive. However, when a hot melt adhesive that is heated and melted is used as an adhesive, the following problems are encountered. There is.

  That is, when a bathroom wall material is manufactured on an industrial manufacturing line using a hot melt adhesive, the following manufacturing process is assumed. First, a surface material film provided with a hot melt adhesive layer on one surface is fed to a metal plate to be conveyed. Then, the metal plate and the surface material film are sandwiched between a pair of hot rolls so that the hot melt adhesive layer is in contact with the plate surface of the metal plate, the hot melt adhesive layer is melted, and then cooled to be bonded. Do.

  However, in this manufacturing process, since the metal plate and the surface material film are bonded in a state where the hot melt adhesive is melted, the surface material film is likely to have wrinkles, and air is generated between the metal plate and the surface material film. Easy to mix.

  In order to suppress the generation of wrinkles and air, it is necessary to apply tension to the surface material film fed to the metal plate to be conveyed. However, if a strong tension is applied, the surface material film may be stretched. Therefore, it is necessary to select a material that does not easily stretch the surface material film. Therefore, it may become a restriction | limiting at the time of material selection of a surface material film.

  The present invention has been made in view of the circumstances as described above, and when the metal plate and the surface material film are bonded with a hot melt adhesive, the occurrence of wrinkles in the surface material film or the metal plate and the surface material. It aims at providing the manufacturing method of the wall material for bathrooms which can suppress mixing of the air between films.

In order to solve the above problems, a method for manufacturing a bathroom wall material of the present invention is a method for manufacturing a bathroom wall material in which a surface material film is bonded to a metal plate, and includes the following steps (A) and (B ) Is included:
(A) A flexible surface material film having a hot melt adhesive layer provided on one surface is fed to a metal plate to be conveyed so that the hot melt adhesive layer is in contact with the plate surface of the metal plate. A step of sandwiching the metal plate and the surface material film from both outer sides with a pair of first heat rolls and softening the hot melt adhesive layer; and (B) a metal plate downstream of the first heat roll in the conveying direction of the metal plate And the surface material film are sandwiched from both outsides by a pair of second heat rolls, the hot melt adhesive layer is melted, and then cooled to bond the metal plate and the surface material film.

  According to the present invention, when a metal plate and a surface material film are bonded with a hot melt adhesive, generation of wrinkles in the surface material film and mixing of air between the metal plate and the surface material film can be suppressed. .

It is a side view which shows roughly one Embodiment of the manufacturing method of the wall material for bathrooms of this invention. It is a chart which shows an example of the heat flow of a hot-melt-adhesive agent layer. It is a side view which shows schematically another embodiment of the manufacturing method of the wall material for bathrooms of this invention.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a side view schematically showing an embodiment of a method for producing a bathroom wall material of the present invention. The method for manufacturing a bathroom wall material according to the present embodiment shown in FIG. 1 is a method for manufacturing a bathroom wall material in which a surface material film 2 is bonded to a metal plate 1, and includes the following steps (A) and (B). Including.

  In the step (A), a flexible surface material film 2 having a hot melt adhesive layer 4 provided on one surface is fed to the metal plate 1 to be conveyed. Then, the metal plate 1 and the surface material film 2 are sandwiched between the pair of first heat rolls 12a and 12b so that the hot melt adhesive layer 4 is in contact with the plate surface of the metal plate 1, and the hot melt adhesive layer 4 is Soften.

  In the step (B), the metal plate 1 and the surface material film 2 are sandwiched between the pair of second heat rolls 13a and 13b downstream from the first heat rolls 12a and 12b in the transport direction D of the metal plate 1, The hot melt adhesive layer 4 is melted. Then, the metal plate 1 and the surface material film 2 are adhere | attached by cooling.

  Thus, in the first stage first heat rolls 12a and 12b in the step (A), the hot melt adhesive layer 4 is not melted and bonded, but softened and temporarily attached. That is, the roll surface temperature of the first heat rolls 12a and 12b is set to a temperature before the hot melt adhesive layer 4 is melted, that is, a softening temperature, and is temporarily attached. In the second heat rolls 13a and 13b in the second stage in the step (B), the roll surface temperature is set to be equal to or higher than the temperature at which the hot melt adhesive layer 4 is melted, and this is pasted. In the first heat rolls 12a and 12b, since the hot melt adhesive layer 4 is not melted, the first heat rolls 12a and 12b can be stretched even if the surface material film 2 has wrinkles. In addition, since the hot melt adhesive layer 4 is not melted by heating with the first heat rolls 12a and 12b, it is not completely bonded, so that the surface material film 2 can be squeezed by pressurization of the first heat rolls 12a and 12b. is there. Thereby, the air between the metal plate 1 and the surface material film 2 can be extracted.

  Below, the manufacturing method of the wall material for bathrooms of this embodiment is demonstrated in order of a process.

  In the step (A), the metal plate 1 is transported in the transport direction D. The means for transporting the metal plate 1 is not particularly limited as long as the device can transport and drive the metal plate 1 at a predetermined speed. For example, a conventionally known conveyor device or the like can be used.

  The metal plate 1 is not particularly limited. For example, a cold-rolled steel plate, a hot-dip galvanized steel plate, an electrogalvanized steel plate, a hot-dip zinc / aluminum alloy-plated steel plate, a hot-dip zinc / aluminum / magnesium alloy-plated steel plate, a tin-plated steel plate And various steel plates such as tin-free steel and stainless steel plate, aluminum alloy plates, nickel alloy plates, titanium alloy plates and the like.

  Although the thickness of the metal plate 1 is not specifically limited, For example, it is 0.3-1.0 micrometer.

  A printed layer may be formed on the metal plate 1 by a printing method such as gravure printing, offset printing, or screen printing in order to improve design properties. The pattern of the print layer is arbitrary, and examples thereof include a stone pattern, a grain pattern, a geometric pattern, and an abstract pattern. In this case, by making the surface material film 2 transparent or translucent, the printed layer of the metal plate 1 can be projected on the surface via the surface material film 2.

  The plate surface opposite to the side to which the surface material film 2 of the metal plate 1 is bonded may be coated with an epoxy resin or the like so as to be easily bonded to the wall surface during construction, or a gypsum board A core material such as the above may be attached.

  As shown in FIG. 1, the surface material film 2 is fed from the feed roll 11 to the metal plate 1 being conveyed, and merges with the metal plate 1 at the position of the pair of first heat rolls 12 a and 12 b. Between the feed roll 11 and the pair of first heat rolls 12a and 12b, the surface material film 2 is fed with a weak tension applied, and the hot melt adhesive layer 4 is placed on the plate surface of the metal plate 1. It is sent to touch.

  The surface material film 2 is formed by laminating a resin film 3 and a hot melt adhesive layer 4. The material of the resin film 3 which is the base material of the surface material film 2 can be appropriately selected in consideration of chemical resistance that is difficult to be affected by chemicals such as detergent used in the bathroom, and scratch resistance of the surface. it can. Examples of the material of the resin film 3 include polyester resins such as polyethylene terephthalate (PET) resin and polybutylene terephthalate (PBT) resin, and polyolefin resins.

  The resin film 3 may contain various additives such as pigments for coloring in addition to the above materials.

  The resin film 3 may be subjected to fine embossing in order to deluster, or may have a mirror finish.

  The resin film 3 may be a transparent layer or a concealing layer for concealing the color of the metal plate 1 so as not to cause uneven color. Moreover, the laminated body of multiple types of resin film may be sufficient. The resin film 3 may form a printing layer by a printing method such as gravure printing, offset printing, or screen printing in order to improve design properties. The pattern of the print layer is arbitrary, and examples thereof include a stone pattern, a grain pattern, a geometric pattern, and an abstract pattern.

  Although the thickness of the resin film 3 is not specifically limited, For example, it is 20-80 micrometers.

  The hot melt adhesive used for the hot melt adhesive layer 4 is melted by heating, thermally fused to the metal plate 1, and then solidified by cooling to adhere to the metal plate 1. Examples of the hot melt adhesive used for the hot melt adhesive layer 4 include polyurethane, polyester, polyolefin, acrylic, ethylene-vinyl acetate, polyamide, nylon, polystyrene, epoxy, and cellulose. System, reactive hot melt system, rubber system and the like.

  The hot melt adhesive may optionally contain components such as a tackifier, a plasticizer, and a wax in addition to a resin component such as a thermoplastic resin as a main component.

  Although the thickness of the hot-melt-adhesive agent layer 4 is not specifically limited, For example, it is 20-80 micrometers.

  Of the pair of first heat rolls 12 a and 12 b, the first heat roll 12 a is in contact with the surface of the surface material film 2 opposite to the hot melt adhesive layer 4 and applies tension. The 1st heat roll 12b touches the plate surface on the opposite side to the surface material film 2 of the metal plate 1 conveyed. The pair of first heat rolls 12a and 12b is preferably rotatable in the transport direction D around the roll axis. As the first heat rolls 12a and 12b, a roll having a material having good thermal conductivity on the roll surface, for example, a metal roll can be used. Moreover, it is preferable to provide a heating means capable of heating and holding the roll surfaces of the first heat rolls 12a and 12b at a constant temperature and a means capable of adjusting the clearance between the first heat rolls 12a and 12b.

  In the first heat rolls 12a and 12b in the first stage in the step (A), the hot melt adhesive layer 4 is not melted and bonded, but is softened and temporarily attached. By temporarily sticking, the surface material film 2 is not rolled up before reaching the second heat rolls 13a and 13b. And in the 1st heat roll 12a, 12b, since the hot-melt-adhesive agent layer 4 is not fuse | melted, even if the surface material film 2 has wrinkles, it can be extended with the 1st heat roll 12a, 12b. In addition, since the hot melt adhesive layer 4 is not melted by heating with the first heat rolls 12a and 12b, it is not completely bonded, so that the surface material film 2 can be squeezed by pressurization of the first heat rolls 12a and 12b. is there. Thereby, the air between the metal plate 1 and the surface material film 2 can be extracted. Furthermore, since generation | occurrence | production of wrinkles and mixing of air can be suppressed, the tension | tensile_strength of the surface material film 2 should just be set to the minimum so that the surface material film 2 may not loosen. Therefore, it can suppress that elongation occurs in the surface material film 2, and the range of material selection of the resin film 3 is expanded.

  In the present embodiment, the temperature at which the hot melt adhesive layer 4 is softened (hereinafter also referred to as the softening temperature) can be measured by differential scanning calorimetry (DSC). Specifically, it can be measured from the point where the heat flow is lower than the extrapolation curve between the point at which the endotherm begins and the point at which the endotherm begins at the low temperature side and the high temperature side from the endothermic peak in the DSC curve. FIG. 2 is a chart showing an example of the heat flow of the hot melt adhesive layer 4. In the example shown in FIG. 2, the softening temperature of the hot melt adhesive layer 4 is about 72.degree. The temperature increase rate of the differential scanning calorimeter is 2 ° C./min. The set temperature of the roll surfaces of the first heat rolls 12 a and 12 b is set to 80 ° C., which is lower than about 104 ° C. which is the melting temperature of the hot melt adhesive layer 4.

  The softening temperature of the hot melt adhesive layer 4 is preferably 50 to 100 ° C.

  Next, the temporarily bonded laminate 5 of the metal plate 1 and the surface material film 2 is subjected to the step (B) downstream of the first heat rolls 12 a and 12 b in the transport direction D of the metal plate 1.

  In the step (B), the metal plate 1 and the surface material film 2 are sandwiched from both outer sides by a pair of second heat rolls 13a and 13b, and the hot melt adhesive layer 4 is melted. Of the pair of second heat rolls 13a and 13b, the second heat roll 13a is in contact with the surface of the surface material film 2 opposite to the hot melt adhesive layer 4, and the second heat roll 13b is a metal to be conveyed. The plate 1 is in contact with the plate surface opposite to the surface material film 2. The pair of second heat rolls 13a and 13b is preferably rotatable in the transport direction D around the roll axis. As the second heat rolls 13a and 13b, a roll having a material having good thermal conductivity on the roll surface, for example, a metal roll can be used. Moreover, it is preferable to provide a heating means that can heat and hold the roll surfaces of the second heat rolls 13a and 13b at a constant temperature and a means that can adjust the clearance between the second heat rolls 13a and 13b.

  Thereafter, the laminate 5 of the metal plate 1 and the surface material film 2 conveyed downstream of the second heat rolls 13a and 13b is cooled, whereby the metal plate 1 and the surface material film are formed by the hot melt adhesive layer 4. 2 are bonded together.

  In this embodiment, the temperature at which the hot melt adhesive layer 4 is melted (hereinafter also referred to as the melting temperature) can be measured by differential scanning calorimetry. Specifically, it can be measured from an extrapolated straight line fitting to the peak low temperature side in the maximum endothermic peak of the heat flow of the DSC curve. In the example shown in FIG. 2, the melting temperature of the hot melt adhesive layer 4 is about 104 ° C. The set temperature of the roll surfaces of the second heat rolls 13a and 13b is 130 ° C., which is higher than that.

  The difference between the temperature at which the hot melt adhesive layer 4 is softened in the step (A) and the temperature at which the hot melt adhesive layer 4 is melted in the step (B) is such that the temperature at which the hot melt adhesive layer 4 is melted is 10 to 10. It is preferably 60 ° C higher. Thereby, generation | occurrence | production of the flaw in the surface material film 2 and mixing of the air between the metal plate 1 and the surface material film 2 can be suppressed especially.

  The bathroom wall material manufactured by the manufacturing method of the present embodiment can be used for a bathroom wall panel constituting a side wall, a bathroom ceiling panel constituting a ceiling, and the like in a bathroom such as a unit bath or a system bath. . The unit bath is for apartments, and the system bus is for detached houses. The walls, floors, ceilings, and other components that make up the bathroom are pre-formed at the factory and assembled at the construction site. Connection between bathroom wall panels, bathroom ceiling panels, and connection between bathroom wall panels and bathroom ceiling panels, for example, by joining edges of adjacent panels and joining bolts, nuts, rivets, etc. It is performed by means such as tools or welding. A heat insulating material can be provided on the back of the outdoor wall of the bathroom wall panel.

  According to the method for manufacturing a bathroom wall material of the present embodiment described above, when the metal plate 1 and the surface material film 2 are bonded with a hot melt adhesive, generation of wrinkles in the surface material film 2 or metal Mixing of air between the plate 1 and the surface material film 2 can be suppressed.

  FIG. 3 is a side view schematically showing another embodiment of the method for producing a bathroom wall material of the present invention. In addition, the same code | symbol is attached | subjected to the element same as embodiment shown in FIG. 1, and the detailed description is abbreviate | omitted.

  In the present embodiment, the metal plate 1 is preheated upstream of the first heat rolls 12a and 12b in the transport direction D of the metal plate 1 and before the step (A). As a means for this preheating, a pair of heat rolls 10a and 10b are arranged.

  The metal plate 1 is sandwiched between a pair of heat rolls 10a and 10b and preheated upstream of the pair of first heat rolls 12a and 12b. The surface material film 2 is fed from the feed roll 11 to the conveyed metal plate 1 and preliminarily heated by the pair of heat rolls 10a and 10b, and the positions of the pair of first heat rolls 12a and 12b. Join at.

  Thereby, as process (A), the hot-melt-adhesive agent layer 4 is softened in the 1st heat rolls 12a and 12b, and is temporarily attached. Here, in the present embodiment, since the metal plate 1 is preheated, the softening temperature of the hot melt adhesive layer 4 can be easily reached.

  Considering that the preheating can easily reach the softening temperature of the hot melt adhesive layer 4 in the first heat rolls 12a and 12b, the metal plate 1 can be preheated in the range of 30 to 80 ° C. preferable.

  Although the present invention has been described above based on the embodiments, the present invention is not limited to these embodiments, and various modifications and changes can be made without departing from the scope of the invention. For example, if necessary for bonding the metal plate 1 and the surface material film 2, a pair of heats that melt the hot melt adhesive layer 4 downstream of the pair of second heat rolls 13 a and 13 b and similarly to this. A roll may be disposed and the main pasting may be performed in two or more stages.

DESCRIPTION OF SYMBOLS 1 Metal plate 2 Surface material film 4 Hot-melt-adhesive agent layer 12a, 12b A pair of 1st heat roll 13a, 13b A pair of 2nd heat roll D Conveying direction

Claims (3)

A method for manufacturing a wall material for a bathroom in which a surface material film is bonded to a metal plate, comprising the following steps (A) and (B):
(A) The flexible surface material film provided with a hot melt adhesive layer on one surface is fed to the metal plate to be conveyed, and the hot melt adhesive layer is a plate surface of the metal plate. Sandwiching the metal plate and the surface material film from both outer sides with a pair of first heat rolls so as to be in contact with each other, and softening the hot melt adhesive layer; and (B) the first in the transport direction of the metal plate; Downstream of one heat roll, the metal plate and the surface material film are sandwiched from both sides by a pair of second heat rolls, the hot melt adhesive layer is melted, and then cooled to cool the metal plate and the surface The process of bonding the material film.   The difference between the temperature at which the hot melt adhesive layer is softened in the step (A) and the temperature at which the hot melt adhesive layer is melted in the step (B) is the temperature at which the hot melt adhesive layer is melted. It is 10-60 degreeC high, The manufacturing method of the wall material for bathrooms of Claim 1 characterized by the above-mentioned.   The bathroom wall material according to claim 1 or 2, wherein the metal plate is preheated upstream of the first heat roll in the transport direction of the metal plate and before the step (A). Production method.

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