JP6892224B2 - How to manufacture wall panels - Google Patents

Description

The present invention relates to a method for manufacturing a wall panel, for example, a method for manufacturing a wall panel in a bathroom, which is printed by inkjet.

Since there are many types of color patterns for wall panels such as bathrooms, it is necessary to prepare a large amount of inventory in order to ship them in a short lead time. By painting this color pattern immediately before shipment, inventory can be unnecessary or reduced, and the variation of the pattern can be increased. As described above, inkjet printing is effective as a means for painting immediately before shipment.

Conventionally, it is well known that the surface is inkjet printed as a decoration for a wall panel (see Patent Documents 1 to 4).

Patent Document 1 is a metal in which an inkjet receiving layer is provided on a metal substrate, a colored pattern is formed on the inkjet receiving layer by inkjet printing, a transparent resin is sprayed to provide a protective film layer, and then the metal is bent into a predetermined panel shape. The manufacturing method of the decorative panel is described.

Patent Document 2 describes a panel in which inkjet printing is performed on a substrate and then the substrate is bent to form a flange. Patent Document 3 describes a decorative board formed by bending a base material after performing inkjet printing and applying clear. Patent Document 4 describes a decorative panel in which a base material is bent and then inkjet printed to give a pattern.

The applicant bends the outer circumference of the base material to form a bent portion, attaches a reinforcing material (gypsum board) to the back surface of the base material with an adhesive, and laminates the wall panel main body to form the wall panel main body. We have proposed a technique for providing a pattern layer by performing inkjet printing on the surface of the base material of the above (Japanese Patent Application No. 2015-10609).

Japanese Unexamined Patent Publication No. 10-296906 JP-A-2007-197931 Japanese Patent No. 5274752 JP-A-2007-245467

The present invention is not merely a method for manufacturing a metal decorative panel formed by subjecting a base material to inkjet printing and bending, but bending an end portion of the base material to form a bent portion on the back surface of the base material. It is a method of manufacturing a wall panel formed by laminating reinforcing materials (gypsum board), and for a wall panel provided with a pattern layer and a clear layer on the surface, a pattern layer in a stable finished state with good printing accuracy. It is an invention for the purpose of obtaining a wall panel provided with a clear layer.

In inkjet printing, if the clearance between the surface of the base material and the inkjet head is too small, the inkjet head collides with the surface of the base material, and if it is large, the landing accuracy of the inkjet deteriorates. Therefore, it is necessary to keep the clearance between the surface of the base material and the inkjet head constant.

However, the edge of the base material is bent to form a bent portion, a reinforcing material is laminated on the back surface of the base material to form the wall panel main body, and inkjet printing is performed on the surface of the base material of the wall panel main body to perform inkjet printing. According to the technique of providing the layer, the thickness tolerance of the base material and the thickness tolerance of the reinforcing material are piled up, and it is not easy to keep the clearance between the base material surface and the inkjet head constant. Further, if the base material is bent after the clear layer is formed, cracks or the like may occur in the clear layer having a film thickness generally thicker than that of the pattern layer.

The present invention is a wall panel formed by bending an end portion of a base material to form a bent portion and laminating a reinforcing material (gypsum board) on the back surface of the base material by inkjet printing on the surface of the base material. An object of the present invention is to realize a method for manufacturing a wall panel in a stable finished state for a wall panel provided with a handle layer.

In order to solve the above problems, the present invention is an inkjet printing method for printing a pattern layer on a base material in a method for manufacturing a wall panel in which a pattern layer is provided on the surface of the base material and the edges of the base material are bent. After the step, the bending step of bending the end portion of the base material to the back side to form a bent portion and the quick-drying property on substantially the entire back surface of the base material excluding the bent portion provided at the end portion of the base material. There is a reinforcing material pasting process in which the front surface of the reinforcing material, which is approximately the same height as the bent part , faces the back surface of the base material, abuts each other, and is bonded and pasted by applying pressure. A clear coating process is provided in which a clear layer is applied on the pattern layer after the material pasting process. In the inkjet printing process, the clearance between the inkjet head and the surface of the base material is kept substantially constant, which is a bending allowance. Provided is a method for manufacturing a wall panel, which comprises printing on the surface of a base material except for an end portion of a material.

It is preferable that the inkjet printing step, the bending step, the reinforcing material pasting step, and the clear coating step are continuously performed in-line.

According to the method for manufacturing a wall panel according to the present invention, in the present invention, after inkjet printing is performed in a state where the surface of the base material has the highest smoothness to form a pattern layer, the end portion of the base material is bent and folded. Since it is a method of forming a curved portion and laminating a reinforcing material (gypsum board) on the back surface of a base material to manufacture a wall panel, it is possible to form a highly accurate pattern layer and a clear layer, and the wall panel is in a stable finished state. Can be obtained.

It is a figure explaining the Example of the manufacturing method of the wall panel which concerns on this invention, (a) and (b) are the perspective view and the partial sectional view of the flat base material, (c), (d). Is a perspective view and a partial cross-sectional view showing a state in which a pattern layer is printed on the surface of a flat plate-shaped base material by inkjet printing. It is a figure explaining the manufacturing method of the wall panel of the said Example, (a) shows the state which the end part of the base material was bent, and (b) is the state before adhering the reinforcing material to the base material together. It is a perspective view which shows. (A) shows a wall panel main body formed by adhering a base material on which a pattern layer is printed and a reinforcing material, and (b) is a partial cross-sectional view of a wall panel manufactured by the wall panel manufacturing method of the above embodiment. Is shown. It is a figure explaining the application example of the wall panel of the said Example, and (a) is the figure which shows a part of the wall panel of the application example (the side end part on the left side when the wall panel was seen from the back surface side). (B) is a figure which shows the BB cross section of (a). It is a figure explaining the connection of two wall panels in order to explain the feature of the wall panel of the said application example, (a) is a perspective view which shows two adjacent wall panels, and (b) is connection. It is a perspective view which shows the material, (c) is a plan view which shows the connecting structure of two wall panels.

A mode for carrying out the method for manufacturing a wall panel according to the present invention will be described below with reference to the drawings based on examples.

Examples of the method for manufacturing a wall panel according to the present invention will be described with reference to FIGS. 1 to 3. As shown in a partial cross-sectional view in FIG. 3B, the wall panel 1 manufactured by the method for manufacturing a wall panel according to the present invention has a base material 2 bonded to each other with an adhesive 13 as a main component. A wall panel main body 4 made of a reinforcing material 3 is provided.

More specifically, as the base material 2, as shown in FIGS. 1A and 1B, a plated steel sheet 6 having a soft resin layer 5 on its surface is used. The base material 2 will be described later, but after the pattern layer 7 is printed on the front surface thereof by inkjet printing, the base material 2 is bent and the reinforcing material 3 is adhered to the back surface thereof with a quick-drying adhesive to form the wall panel main body 4.

Further, a clearing agent is applied to the surface of the pattern layer 7 to form the clear layer 8. In the present specification and the present invention, the "pattern layer" refers to a layer that forms a color, a pattern, a pattern, a design, and the like.

A gypsum board is used as the reinforcing material 3. If the reinforcing material 3 has poor flatness and is uneven, the base material 2 or the pattern layer 8 adhered to the surface of the reinforcing material 3 is also uneven. Therefore, the gypsum board used as the reinforcing material 3 has a thickness of about 8 to 20 mm. Yes, the one with an accuracy of 1 mm or less in the thickness variation is used. The reinforcing material 3 is not limited to gypsum board, and a material formed of two layers of a heat insulating material and gypsum board may be used.

Hereinafter, the details of the method for manufacturing a wall panel according to the present invention will be described in order of steps, and the features thereof will be clarified.

(1) Printing Step The pattern layer as shown in FIGS. 1 (c) and 1 (d) is printed on the surface of the soft resin layer 5 of the flat plate-shaped base material 2 shown in FIGS. 1 (a) and 1 (b) by inkjet printing. 7 is formed. When this inkjet printing is performed, the printing is not performed on the bending allowance (folding margin) 9 of the base material 2 to be bent.

In this embodiment, the bending allowance 9 is the outer circumference (end portion) of the portion to be printed, and the width thereof is, for example, about 8 mm to 20 mm. Even if the mist-like ink is slightly scattered on the bending allowance 9, it becomes a shielding part (a part that cannot be seen in the used state) by the bending process to the back surface side (the side opposite to the pattern layer 7) described later, so that it looks. Does not get worse and does not matter.

Since the thickness variation of the base material 2 is very small, for example, about several microns, it is possible to keep the clearance (gap) between the inkjet head and the surface 15 of the base material 2 almost constant and stable. Become. Therefore, the pattern layer 7 can be formed by inkjet printing in a stable finished state with good printing accuracy.

(2) Bending step of the bent portion of the base material The bending allowance 9 (see FIG. 1 (c)) of the base material 2 in which the pattern layer 7 is inkjet-printed on the front surface is shown on the back surface 11 as shown in FIG. 2 (a). A bent portion 10 is formed on the side by bending by a bending process.

The bending height of the bent portion 10 (the height at which the end portion of the base material 2 is bent and rises from the back surface 11 thereof) h is substantially the same as the thickness t of the reinforcing material 3 (see FIG. 2B). It depends on the thickness of the reinforcing material 3, but is, for example, about 8 mm to 20 mm. Here, substantially the same dimensions mean that the difference between the bending height h of the bent portion 10 and the thickness t of the reinforcing member 3 is within 2 mm.

(3) Reinforcing Material Pasting Step Next, the reinforcing material 3 is prepared, and the quick-drying adhesive 13 is applied to the front surface 12 of the reinforcing material 3 to be the sticking surface or the back surface 11 of the base material 2. Here, the quick-drying adhesive means an adhesive that cures within 15 minutes, for example.

Then, as shown in FIG. 2B, the front surface 12 of the reinforcing material 3 faces the back surface 11 of the base material 2, comes into contact with each other and adheres to each other by applying pressure, and as shown in FIG. 3A. , The reinforcing material 3 is attached to the back surface 11 of the base material 2, and the wall panel main body 4 on which the pattern layer 7 is already formed is formed on the front surface 15.

(4) Clear coating step Next, a clearing agent is applied to the surface 16 of the pattern layer 7 formed on the surface 15 of the base material 2 to form the clear layer 8 as shown in FIG. 3 (b). The clear layer 8 is made of a transparent or translucent resin film, and protects the pattern layer 7 and imparts gloss.

As shown in FIG. 3B, the base material 2 is adhered to the surface 12 of the reinforcing material 3, and the pattern layer 7 by inkjet is further attached to the surface 15 of the base material 2 by the method for manufacturing the wall panel including the steps. The wall panel 1 of the present invention is manufactured, which is formed and further formed with a clear layer 8 formed on the surface 16 of the pattern layer 7.

As described above, in the method for manufacturing a wall panel in which the pattern layer 7 is provided on the surface of the base material 2 of the present invention, the surface 15 of the base material 2 is inkjet printed to form the pattern layer 7, and then the base material is formed. The bending allowance 9 at the end of 2 is bent toward the back surface side to form the bent portion 10, and the back surface 11 of the base material 2 is reinforced having a thickness t having substantially the same dimensions as the bending height h of the bent portion 10. The method is characterized in that the material 3 is attached and the clear layer 8 is further formed on the surface 16 of the pattern layer 7, and these steps are continuously performed in-line.

As described above, the bending allowance 9 at the end of the base material 2 is bent to form the bent portion 10, and the reinforcing material 3 is laminated on the back surface of the base material 2 to form the wall panel main body 4, and the wall panel main body 4 is formed. According to the manufacturing method in which inkjet printing is performed on the surface 15 of the base material 2 and the pattern layer 7 is provided, the thickness tolerance of the base material 2 and the thickness tolerance of the reinforcing material 3 are accumulated, and the surface 15 of the base material 2 and the inkjet head It is not easy to keep the clearance between them constant.

However, according to the method for manufacturing a wall panel according to the present invention, the base material 2 having the highest smoothness (thickness variation is, for example, about several microns) before bending and laminating the reinforcing material 3. In order to perform inkjet printing on the surface 15, stable printing is possible with the clearance between the surface 15 of the base material 2 and the inkjet head being substantially constant, so that printing accuracy is improved and a stable finish is achieved. The pattern layer 7 can be obtained in the state.

Further, if the base material 2 is bent after the formation of the clear layer 8, cracks or the like may occur in the clear layer 8 having a film thickness generally thicker than that of the pattern layer 7, but after the bent portion 10 is formed. By applying the clear coating after attaching the reinforcing material 3 having substantially the same height as the bent portion 10, the clear layer 8 is secured with the smoothness required for more stable clear coating without causing cracks or the like. Can be formed.

(Application example)
The above configuration is a basic configuration of an embodiment of the method for manufacturing a wall panel of the present invention, but further, a wall of the above embodiment can be used depending on usage conditions such as connection between wall panels and use of the wall panel. The panel manufacturing method is applied to various types of wall panel manufacturing methods, and one such application example will be described in the wall panel 21 manufacturing method having the configuration shown in FIGS. 4 and 5. ..

The manufacturing method of the wall panel 21 of this application example is basically the same as the manufacturing method of the wall panel of the above embodiment, but the wall panel 21 has a configuration for connecting adjacent wall panels to each other. Therefore, it is characterized by adding a process for that purpose. The following will be described focusing on the steps that are characteristic of the wall panel manufacturing method of this application example.

In the method for manufacturing the wall panel of the application example, first, as in the case of the above embodiment, the surface 15 of the base material 2 is printed by inkjet printing, as in the method of manufacturing the wall panel of the above embodiment. c) As shown in (d), the pattern layer 7 is printed.

Next, the bending allowance at the end of the base material 2 is bent to form the bent portion, which will be described in more detail. At the upper end of the base material 2, as shown in FIGS. 4A and 4B, a horizontal bent portion 23 (indicated by a two-dot chain line in FIG. 4B) is formed toward the back surface side. Further, it is folded downward to form the folded portion 24.

The bending height h of the horizontal bent portion 23 (see FIG. 4B) is the thickness t of the reinforcing material 3 (see FIG. 4B), similarly to the bending height h of the bent portion 10 of the embodiment. ) Is almost the same size as). Similarly, although not shown, the lower end portion of the wall panel 21 also forms a horizontal bent portion 23 and an upward folded portion 24.

In order to connect the two adjacent wall panels 21 to each other, at the left and right side ends of the wall panel 21, the base material 2 is bent toward the back surface side as shown in FIGS. 4 (a) and 4 (b), respectively. A vertical bent portion 28 is formed, and a vertical folded portion 29 along the back surface 11 of the base material 2 is further formed. The bending height h of the vertical bent portion 28 is substantially the same as the thickness t of the reinforcing member 3.

A vertical crosspiece 32 is inserted into a space surrounded by a main surface portion 30 (front surface 15 and back surface 11), a bent portion 23, and a folded portion 29 of the base material 2 at the side end portion of the wall panel 21, and FIG. As shown in (a), the folded-back portion 29 and the vertical rail 32 are fixed by the fixing portion 33 formed by engaging the dowel formed in advance in the folded-back portion 29 with the dowel hole formed in advance in the vertical rail 32.

Then, in the same manner as in the above embodiment, the reinforcing material 3 is adhered to the back surface 11 of the base material 2 with the quick-drying adhesive 13 to form the wall panel main body. Further, as in the case shown in FIG. 3B of the above embodiment, a clearing agent is applied to the surface of the pattern layer 7 to form the clear layer 8. As a result, the wall panel 21 of the application example is formed.

A configuration for connecting two wall panels 21 formed by the method for manufacturing a wall panel of such an application example will be described with reference to FIG. 5 below for reference. As shown in FIG. 5A, two wall panels 21 connected to each other are arranged adjacent to each other on the left and right sides.

Then, by using the connecting member 35 as shown in FIGS. 5 (b) and 5 (c) having the tapered protrusion 34 on the surface, the protrusion 34 is made into the slit 37 for fitting the connecting member formed on the vertical rail 32. By fitting, the two wall panels 21 can be connected as shown in FIG. 5 (c). A joint material 38 is charged to the connecting end of the two wall panels 21 as needed.

Although the embodiment for carrying out the method for manufacturing a wall panel according to the present invention has been described above based on examples, the present invention is not limited to such examples and is described in the scope of claims. It goes without saying that there are various examples within the scope of the technical matters.

Since the method for manufacturing a wall panel according to the present invention has the above-described configuration, a method for manufacturing a wall panel for various purposes such as for structure and partition of various parts of a building as well as a wall panel for a bathroom. It is also applicable as.

1 Wall panel 2 Base material 3 Reinforcing material 4 Wall panel body 5 Soft resin layer 6 Plated steel plate 7 Pattern layer 8 Clear layer 9 Bending allowance 10 Folded part 11 Back side of base material 12 Surface of reinforcing material 13 Adhesive 15 Of base material Surface 16 Surface of pattern layer 21 Wall panel 23 Folded part at the upper and lower ends of the base material 24 Folded part at the upper and lower ends of the base material 28 Folded part at the side end of the base material 29 Folded part at the side end of the base material Part 30 Main surface of the base material 32 Vertical rail 33 Folded part of the base material and fixed part of the vertical rail 34 Tapered protrusion 35 Connecting material 37 Slit of the vertical rail 38 Joint material

Claims (2)

In a method for manufacturing a wall panel in which a pattern layer is provided on the surface of a base material and the edges of the base material are bent, the edges of the base material are sequentially printed after the inkjet printing step of printing the pattern layer on the base material. A bending process of folding the part to the back side to form a bent part, and applying a quick-drying adhesive to almost the entire back surface of the base material excluding the bent part provided at the end of the base material to form a bent part. A reinforcing material pasting process is provided in which the front surface of the reinforcing material having substantially the same height faces the back surface of the base material, abuts each other, and is bonded and pasted by applying pressure. After the reinforcing material pasting process, a clear layer is provided on the pattern layer. In the inkjet printing process, the clearance between the inkjet head and the surface of the base material is kept substantially constant, and the surface of the base material is excluded except for the edge of the base material, which is a bending allowance. A method of manufacturing a wall panel, which comprises printing on. The method for manufacturing a wall panel according to claim 1, wherein the inkjet printing step, the bending step, the reinforcing material pasting step, and the clear coating step are continuously performed in-line.

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