Building panel material production method, mold, and building panel material

Abstract

Provided are a building-use panel production method, a mold for use in this production method, and a building-use panel produced by this production method, all of which are capable of minimizing the number of steps, where both a design pattern and a fastening pattern that defines fastening positions of fasteners are formed on a wide surface of the building-use panel. In the building-use panel production method, a plurality of design patterns 20 and a plurality of fastening patterns 30 that define positions of fasteners are formed at a same time on a wide surface 11 that is a front surface of a building-use panel. More specifically, the production method includes a cutting step of cutting a base sheet for building-use panels into predetermined planar dimensions, to produce a product-use panel 10, and a press-forming step of forming, by press-forming, both the design-pattern groove 20 included in the design pattern and the fastening-pattern groove 30 included in the fastening pattern at a same time in the one wide surface 11 that is a front surface of the product-use panel 10.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a building-use panel production method, a mold, and a building-use panel.BACKGROUND ART

[0002] When a building-use panel is to be fastened to a ceiling base material or a wall base material by fasteners, on-site marking of multiple fastening positions is first performed on a wide surface of the building-use panel by using what is known as a sumi-dashi (ink marking) technique. However, such on-site marking on the building-use panel is labor-intensive, and this problem becomes more even pronounced when there are many building-use panels or when the wide surface of the building-use panel has a large surface area. Further, the pitch of multiple fastening positions may differ depending on the location and size of the building-use panel. Therefore, it is necessary to mark the fastening positions with these factors in mind, which also contributes to the complexity of on-site marking.

[0003] It is therefore possible to eliminate the complexity of the above-described on-site marking by adding fastening positions to the wide surface of the building-use panel in advance in a factory setting or a similar setting. In the factory setting or a similar setting, the fastening positions are generally added by a method for printing or marking fastening positions on a wide surface of a building-use panel.

[0004] Importantly, it is understood that in a case where a building-use panel is to be used as an interior finishing material or the like, and a design pattern is to be featured on a wide surface thereof, printing or marking the fastening positions requires both a step of forming the design pattern and a step of forming a fastening pattern that defines a fastening position of a fastener, and consequently the number of steps at the time of producing the building-use panel increases and production efficiency decreases.

[0005] Therefore, a building-use panel production method that can minimize the number of steps is desired, where both a design pattern and a fastening pattern that defines the fastening position of a fastener are formed on a wide surface.

[0006] Here, Patent Document (PTL) 1 proposes a method for producing a marked panel. The method for producing the marked panel includes a step of preparing a panel body having a front surface and a rear surface, and a step of adding in advance a plurality of markings, arranged at a predetermined pitch along a first direction parallel to the front surface and the rear surface, on at least one of the front surface or the rear surface of the panel body.CITATION LISTPATENT LITERATURE

[0007] PTL 1: Japanese Patent Application Laid-Open Publication No. 2018-154999SUMMARY OF THE INVENTIONTECHNICAL PROBLEM

[0008] Although the production method of the marked panel in PTL 1 is a production method in which the plurality of markings are added in advance at fastening positions of fasteners on the front surface or the rear surface of the panel body, this related-art patent document does not disclose a technique for addressing the aforementioned issue, namely, minimizing the number of steps when adding, on a wide surface of a building-use panel, both a design pattern and a fastening pattern that defines a fastening position of a fastener.

[0009] The present disclosure provides a building-use panel production method, a mold for use in this production method, and also a building-use panel produced by this production method, all of which are capable of minimizing the number of steps, where both a design pattern and a fastening pattern that defines a fastening position of a fastener are formed on a wide surface of the building-use panel.SOLUTION TO THE PROBLEM

[0010] In a building-use panel production method according to an aspect of the present disclosure, a plurality of design patterns and a plurality of fastening patterns that define positions of fasteners are formed at a same time on a wide surface that is a front surface of a building-use panel.

[0011] Also, a mold according to another aspect of the present disclosure for use when performing press-forming on one wide surface that is a front surface of a product-use panel obtained by cutting a base sheet for building-use panels into predetermined planar dimensions, includes, on a single pressing surface mold, a plurality of design-pattern protrusions for forming a plurality of design-pattern grooves in the wide surface and a plurality of fastening-pattern protrusions for forming a plurality of fastening-pattern grooves in the wide surface, the plurality of fastening-pattern grooves defining fastening positions of fasteners.

[0012] Further, a building-use panel according to another aspect of the present disclosure has a wide surface that is a front surface, wherein the wide surface is provided with a plurality of design-pattern grooves, and wherein a plurality of fastening-pattern grooves are provided at a predetermined pitch along the wide surface, the fastening-pattern grooves defining fastening positions of fasteners.ADVANTAGEOUS EFFECTS OF THE INVENTION

[0013] According to the present disclosure, the number of steps can be minimized where both the design pattern and the fastening pattern that defines the fastening position of the fastener are formed on the wide surface of the building-use panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] [FIG. 1] FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment. [FIG. 2] FIG. 2 is a plan view of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. [FIG. 3] FIG. 3 is an enlarged view of an example of design-pattern protrusions provided in a dispersed manner, and is an enlarged view of section III of FIG. 2. [FIG. 4] FIG. 4 is a plan view illustrating a state in which the design-pattern protrusion and a fastening-pattern protrusion are arranged side by side, and is an enlarged view of section IV of FIG. 2. [FIG. 5] FIG. 5 is a plan view of an example of a building-use panel according to an embodiment. [FIG. 6] FIG. 6 is an enlarged view of an example of design-pattern grooves arranged in a dispersed manner, and is an enlarged view of section VI of FIG. 5. [FIG. 7] FIG. 7 is a plan view illustrating a state in which a design-pattern protrusion and a fastening-pattern groove are arranged side by side, and is an enlarged view of section VII of FIG. 5. [FIG. 8] FIG. 8 is a plan view of other examples of the fastening-pattern groove. [FIG. 9] FIG. 9 is a plan view of another example of a building-use panel according to an embodiment. [FIG. 10] FIG. 10 is an enlarged view of an example of design-pattern protrusions arranged in a dispersed manner, and is an enlarged view of section X of FIG. 9. [FIG. 11] FIG. 11 is a plan view of yet another example of a building-use panel according to an embodiment. [FIG. 12] FIG. 12 is a perspective view of part of another example of a building-use panel according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, a building-use panel production method, a mold, and a building-use panel according to the embodiments are described with reference to the appended drawings. In the specification and drawings, components that are substantially the same are denoted by the same reference numerals, and redundant description thereof is omitted in some cases.[Mold, building-use panel production method, and building-use panel according to embodiments]

[0016] An example of a mold, a building-use panel production method, and a building-use panel according to the embodiments is described with reference to FIGS. 1 to 12. Here, FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment, whereas FIG. 2 is a plan view of an example of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. Also, FIG. 3 is an enlarged view of an example of design-pattern protrusions arranged in a dispersed manner, and is an enlarged view of section III of FIG. 2, whereas FIG. 4 is a plan view illustrating a state in which the design-pattern protrusion and a fastening-pattern protrusion are arranged side by side, and is an enlarged view of section IV of FIG. 2. FIG. 5 is a plan view of an example of a building-use panel according to an embodiment, FIG. 6 is an enlarged view of an example of design-pattern grooves arranged in a dispersed manner, and is an enlarged view of section VI of FIG. 5, whereas, FIG. 7 is a plan view illustrating a state in which a design-pattern groove and a fastening-pattern groove are arranged side by side, and is an enlarged view of section VII of FIG. 5.

[0017] A mold 50 for use in a building-use panel production method is a mold that is for use when forming a design-pattern groove and a fastening-pattern groove in the wide surface 11, during press-forming, by press-forming with the press-forming surface 51 in the X direction, on one wide surface 11 that is the front surface of a product-use panel 10 obtained by cutting a base sheet for building-use panels into predetermined planar dimensions.

[0018] Examples of the product-use panel 10 that is to be subjected to a press-forming step include a gypsum plate, a gypsum board, a calcium silicate board, a particle board, a hardboard, plywood, structural plywood, and the like, but the product-use panel 10 in the illustrated examples is a gypsum board. Also, in addition to a general gypsum board, the gypsum board includes a reinforced gypsum board, an ordinary hard gypsum board, a sheathing hard gypsum board, a moisture absorptive and desorptive reinforced gypsum board, a moisture absorptive and desorptive ordinary gypsum board, a moisture absorptive and desorptive sheathing hard gypsum board, a gypsum plate with a glass fiber nonwoven fabric, a glass mat gypsum board, and the like.

[0019] The gypsum board 10 is a rectangularly-shaped board in plan view in which both wide surfaces of the gypsum board core material are covered with gypsum board liner paper. The planar dimensions of t1 × t2 are set to be, for example, 910 mm × 455 mm, 910 mm × 910 mm, 1,000 mm × 1,000 mm, or 1,000 mm × 500 mm. The thickness of the gypsum board 10 is, for example, 9.5 mm or 12.5 mm. The gypsum board 10 is formed by cutting a base sheet (not illustrated) having planar dimensions of, for example, 1,854 mm × 945 mm into the desired planar dimensions as described above.

[0020] As illustrated in FIG. 2, the press-forming surface 51 of the mold 50 is provided with numerous design-pattern protrusions 60 in a dispersed manner.

[0021] As illustrated in FIG. 3, the design pattern of the numerous design-pattern protrusions 60 is a travertine pattern. That is, as illustrated in FIG. 5, numerous design-pattern grooves 20 exhibiting a travertine pattern are added in a dispersed manner in the wide surface 11 of the gypsum board 10 which is press-formed by the mold 50 having the press-forming surface 51 of the illustrated example. The travertine pattern is also referred to in Japanese as a "bug-eaten pattern", due to its irregular, porous appearance.

[0022] Referring back to FIG. 2, the press-forming surface 51 of the mold 50 has first edges 52 extending along a first direction (horizontal direction in FIG. 2) and second edges 53 extending along a second direction (vertical direction in FIG. 2), forming a rectangular shape in plan view, and a plurality of fastening-pattern protrusions 70 are provided at a predetermined first pitch t3 in straight lines parallel and adjacent to the pair of the first edges 52 among these four edges.

[0023] Also, on the press-forming surface 51, a plurality of fastening-pattern protrusions 70 are provided at a predetermined second pitch t7 in a straight line, in a center region 55, the straight line of the plurality of fastening-pattern protrusions 70 being parallel to the first edges 52.

[0024] As illustrated in FIG. 5, the fastening-pattern protrusions 70 are protrusions for adding, in the wide surface 11 of a building-use panel 40, fastening-pattern grooves 30 that define the fastening positions of fasteners. The building-use panel 40 is fastened by a plurality of non-illustrated fasteners to a non-illustrated ceiling base material or a non-illustrated wall base material. Examples of the fasteners include screws, nails, staples, and the like.

[0025] Referring back to FIG. 2, the first pitch t3 is set to be 150 mm or less than 150 mm, for example, and the second pitch t7 is set to be 200 mm or less than 200 mm, for example. The spacing of the fasteners is preferably set to be a minimum of 50 mm and a maximum of 606 mm, although the spacing varies depending on whether the fasteners are used to fasten the building-use panel forming either the ceiling or wall, and whether the building-use panel is a single sheet or multiple sheets.

[0026] In FIG. 2, length t4 from the second edge 53 to the first fastening-pattern protrusion 70 can be set to be 15 mm, for example, and likewise, length t6 from the first edge 52 to the fastening-pattern protrusion 70 can be set to be 15 mm, for example. In the illustrated example, a plurality of fastening-pattern protrusions 70 in the center region 55 are set to be located at a distance t5 from the first edges 52, t5 being half the length of t2 on the second edges 53.

[0027] As illustrated in FIG. 4, the fastening-pattern protrusions 70 are protrusions that are circular in shape in plan view (including elliptical shape in plan view), whereas the design-pattern protrusions 60 are protrusions designed to replicate a travertine pattern. Therefore, the fastening-pattern grooves 30 formed by the engagement of the fastening-pattern protrusions 70 with the wide surface 11 of the building-use panel 40 are circular grooves in plan view, as illustrated in FIGS. 5 and 7.

[0028] In the illustrated examples, the design-pattern protrusion 60 is arranged adjacent to the fastening-pattern protrusion 70 that is circular in shape in plan view. As illustrated in FIG. 2 and FIG. 4, the design-pattern protrusions 60 are arranged adjacent to each of the fastening-pattern protrusions 70 provided on the press-forming surface 51, and the design-pattern protrusion 60 and fastening-pattern protrusion 70 arranged in a side-by-side manner together form a protrusion unit 75.

[0029] Therefore, the design-pattern grooves 20 formed by the engagement of the design-pattern protrusion 60, in the illustrated example, with the wide surface 11 of the building-use panel 40 are grooves fashioned to replicate a travertine pattern as illustrated in FIGS. 5 and 7.

[0030] Thus, the mold 50 illustrated in FIG. 2 includes, on a single press-forming surface 51 mold 50, a plurality of design-pattern protrusions 60 for forming, in the wide surface 11 of the building-use panel 40, the plurality of design-pattern grooves 20, and the plurality of fastening-pattern protrusions 70 for forming, in the wide surface 11, the plurality of fastening-pattern grooves 30 that define the fastening positions of the fasteners.

[0031] Therefore, when press-forming is performed once on the wide surface 11 of the gypsum board 10 using the mold 50, the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 are formed in the wide surface 11 of the gypsum board 10 at the same time. This mold 50 enables a more efficient building-use panel production method, as it reduces the number of steps required compared to another production method of a building-use panel in which design-pattern grooves 20 and fastening-pattern grooves 30 are formed in separate steps.

[0032] Next, an overview of an example of the building-use panel production method with use of the mold 50 is presented below. First, when the building-use panel 40 illustrated in FIG. 5 is to be produced, the base sheet of the gypsum board (not illustrated) is cut into predetermined planar dimensions to produce the product-use panel 10. The product-use panel 10 is rectangular in shape in plan view, and its planar dimensions are 910 mm × 455 mm, 910 mm × 910 mm, or the like (This is the cutting step.) as described above.

[0033] Next, the mold 50 is used on one wide surface 11 that is the front surface of the product-use panel 10, and press-forming is performed to form the plurality of design-pattern grooves 20 (an example of a design pattern) and the plurality of fastening-pattern grooves 30 (an example of a fastening pattern) at the same time (This is the press-forming step).

[0034] Next, the wide surface 11 that is the front surface of the product-use panel 10 in which the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 have been formed, is surface finished by applying a coating to the wide surface 11 and drying the coating, resulting in the building-use panel 40 illustrated in FIG. 5. A roller coater or the like is used for performing the coating, and a dryer or the like is used for performing drying (This is the coating step).

[0035] By performing this coating step, the wide surface 11 of the building-use panel 40 is colored white or ivory, for example, whereas the design-pattern grooves 20 and the fastening-pattern grooves 30 are not colored, and the gray-colored liner paper with which the gypsum board 10 is equipped is exposed (the liner paper is pushed in towards the rear surface side by the design-pattern protrusions 60 and the fastening-pattern protrusions 70 of the mold 50). Therefore, the contrast between: the design-pattern grooves 20 and the fastening-pattern grooves 30; and the colored wide surface 11 gives a unique appearance design.

[0036] Further, following the coating step, a chamfering step of chamfering the edges of all four sides of the building-use panel may be performed.

[0037] As illustrated in FIG. 5, since the press-forming surface 51 is provided with the protrusion unit 75, a groove unit 35 made up of the fastening-pattern groove 30 and the design-pattern groove 20 that is adjacent thereto is formed at the fastening position of the fastener in the wide surface 11 of the building-use panel 40, and a plurality of the groove units 35 are arranged orderly at the first pitch t1 and the second pitch t2. In addition, as illustrated in FIGS. 5 and 6, numerous design-pattern grooves 20 exhibiting the travertine pattern are dispersed in all regions of the wide surface 11.

[0038] Since the fastening-pattern groove 30 and the design-pattern grooves 20 adjacent thereto form one groove unit 35, it is easier for workers to find each fastening-pattern groove 30 than when the fastening-pattern groove 30 circular in shape in plan view is provided alone.

[0039] Furthermore, since the design-pattern groove 20 forming the groove unit 35 is the same design-pattern groove as the design-pattern grooves 20 of the travertine pattern provided in a dispersed manner, the design-pattern groove 20 included in the groove unit 35 does not detract from the exterior design quality of the building-use panel 40. It is to be noted that the fastening-pattern groove 30 is easier to find when performing fastening if the pattern groove 30 has a design characteristic different from that of the design-pattern groove 20 having a travertine pattern provided in a dispersed manner but this may detract from the design uniformity of the building-use panel 40. Therefore, it is preferable to set the pattern of the fastening-pattern groove 30 in consideration of both factors.

[0040] As illustrated in FIG. 7, the planar dimensions of the fastening-pattern groove 30 circular in shape in plan view is set to be less than or equal to the size of the head of the fastener 18 illustrated by the solid line. In the illustrated examples, the planar dimensions of the fastening-pattern groove 30 are set to be smaller than the sizes of the heads of the fastener 18. Therefore, when the fastener 18 is driven into the fastening-pattern groove 30, the fastening-pattern groove 30 is covered by the head of the fastener 18, and the fastening-pattern groove 30 is unlikely to be seen from the outside. This makes it possible to mitigate degradation in the exterior design quality of the finished surface, such as a loss of the design uniformity of the building-use panel 40 caused by the fastening-pattern grooves 30 being visible from the outside.

[0041] According to the building-use panel production method illustrated in the drawings, by applying the mold 50 to the wide surface 11 of the gypsum board 10 and performing press-forming, the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 can be formed in the wide surface 11 at the same time. This enables a more efficient building-use panel production method, as it reduces the number of steps required compared to another production method of a building-use panel in which design-pattern grooves 20 and fastening-pattern grooves 30 are formed in separate steps.

[0042] The building-use panel 40, in which design-pattern grooves 20 of a plurality of travertine patterns are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30 are provided at a predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30 are provided on Gyptone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0043] Here, FIG. 8 illustrates other examples of the fastening patterns of the fastening pattern groove. The examples illustrated in (a) to (g) in FIG. 8 are, in order, a cross-shaped fastening-pattern groove 30A, an X-shaped fastening-pattern groove 30B, a triangle-shaped (an example of polygonal) fastening-pattern groove 30C, an asterisk-shaped (an example of a special symbol) fastening-pattern groove 30D, an exclamation mark-shaped (another example of a special symbol) fastening-pattern groove 30E, a question mark-shaped (another example of a special symbol) fastening-pattern groove 30F, and a star-shaped (another example of a special symbol) fastening-pattern groove 30G.

[0044] Since fastening-pattern protrusions having shapes complementary to these fastening-pattern grooves are provided on the press-forming surface of the mold, various fastening grooves can be formed in the wide surface 11 of the gypsum board 10. As for these various shapes of fastening-pattern grooves, as illustrated in FIG. 5, a single-type of fastening pattern groove may be provided in the wide surface 11, or multiple types of fastening-pattern grooves may be provided in the wide surface 11. Various fastening pattern shapes other than those illustrated in the drawings may be used.

[0045] Thus far, the building-use panel production method in which the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 in the wide surface 11 of the gypsum board 10 are formed at the same time, has been described using the mold 50. However, as another example of the building-use panel production method of the embodiment, there is also a method for forming the plurality of design patterns and the plurality of fastening patterns at the same time through printing.

[0046] More specifically, there are three possible methods of forming the plurality of design patterns and the plurality of fastening patterns at the same time through printing. One of the methods is to produce a gypsum board using a liner paper for the gypsum board on which a plurality of design patterns and a plurality of fastening patterns are printed in advance, and then cut the gypsum board into predetermined product dimensions. Another method is a forming (printing) method (printing step) in which, during the production of the gypsum board, an unillustrated transfer roll or the like bearing a design-pattern display (another example of the design pattern) and a fastening-pattern display (another example of the fastening pattern) is used to form (print) both pattern displays on a front surface of the board at the same time. Yet another method is a forming (printing) method in which: laminate paper on which a plurality of design patterns and a plurality of fastening patterns are printed in advance is laminated onto the base sheet for building-use panels or onto the product-use panel obtained by cutting the base sheet for building-use panels into predetermined planar dimensions; or an unillustrated transfer roll or the like bearing a design-pattern display (another example of the design pattern) and a fastening-pattern display (another example of the fastening pattern) is used to form (print), at the same time, both pattern displays on a surface of the base sheet for building-use panels or on the product-use panel obtained by cutting the base sheet for building-use panels into predetermined planar dimensions.

[0047] In this way, even with a display (marking) in which both the design pattern and the fastening pattern are printed, by printing both patterns on the base sheet for building-use panels or on the wide surface of the product-use panel at the same time, the number of steps can be minimized, and thus this technique serves as a highly efficient building-use panel production method.

[0048] Next, another example of the building-use panel is described with reference to FIG. 9 and FIG. 10. Here, FIG. 9 is a plan view of another example of a building-use panel according to an embodiment, whereas FIG. 10 is an enlarged view of section X of FIG. 9 and is an enlarged view of another example of the design-pattern grooves arranged in a dispersed manner.

[0049] A building-use panel 40A differs from the building-use panel 40 in that it has the design-pattern grooves 20A featuring the marble pattern instead of the design-pattern grooves 20 with the travertine pattern, and also has star-shaped fastening-pattern grooves 30G, which are special symbols. Here, a form other than the fastening-pattern grooves 30G in the illustrated example may be used as the fastening-pattern grooves.

[0050] The building-use panel 40A, in which a plurality of design-pattern grooves 20A featuring a marble pattern are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30G are provided at pitches t3 and t7 in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30G are provided on Marbletone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0051] Next, yet another example of a building-use panel is described with reference to FIG. 11. Here, FIG. 11 is a plan view of yet another example of a building-use panel according to an embodiment.

[0052] A building-use panel 40B differs from the building-use panels 40 and 40A in that it has star-shaped (an example of a pictorial pattern) design-pattern grooves 20B instead of the design-pattern grooves 20 and 20A featuring the travertine pattern and the marble pattern, respectively, and that it has triangle-shaped fastening-pattern grooves 30C which are different from the star-shaped fastening-pattern grooves 30, 30G. Here, a form other than the fastening-pattern grooves 30C in the illustrated example may be used as the fastening-pattern grooves.

[0053] The building-use panel 40B, in which a plurality of star-shaped design-pattern grooves 20B are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30C are provided at a predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30C are provided on Stellart (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0054] Next, yet another example of a building-use panel is described with reference to FIG. 12. Here, FIG. 12 is a perspective view of part of another example of a building-use panel according to an embodiment.

[0055] A building-use panel 40C is different from the building-use panels 40, 40A, and 40B in that it has a plurality of design-pattern grooves 20C that are through-holes instead of grooves that extend to a position within the gypsum board 10 thickness-wise. Although the cross-shaped fastening-pattern groove 30A is provided at a predetermined pitch, an aspect other than the fastening-pattern grooves 30A in the illustrated example may be used as the fastening-pattern grooves.

[0056] The plurality of through-holes 20C in the illustrated example are provided so as to be arranged in the wide surface 11 in an orderly manner (arranged with multiple grid points) at a predetermined pitch t8 in the vertical and horizontal directions. Here, the pitch t8 can be set to be approximately 22 mm, for example.

[0057] The building-use panel 40C provided with the plurality of through-holes 20C forms a perforated acoustic panel, and the plurality of through-holes 20C serve as design grooves that provide both sound-absorbing and aesthetic functions. As described, the building-use panel 40C, in which the plurality of through-holes 20C are provided in an orderly manner and, further, the plurality of fastening-pattern grooves 30A are provided at the predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30A are provided on Tiger Tone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0058] Here, in a production method in which the plurality of through-holes 20C and the plurality of fastening-pattern grooves 30A are formed in the wide surface 11 at the same time, a mold is used that has a press-forming surface with a plurality of design-pattern protrusions and a plurality of fastening-pattern protrusions, the design-pattern protrusions and the plurality of fastening-pattern protrusions being of different heights (protrusion lengths).

[0059] Other embodiments, such as those in which other components are combined with the above configurations, are also possible, and the present disclosure is not limited to the configurations illustrated here by any means. In this respect, the configurations of the present disclosure may be changed without departing from the purpose of the present disclosure, and the configurations can be appropriately determined according to the usage form.

[0060] This international application claims priority based on Japanese Patent Application No. 2023-129053, filed on August 8, 2023, the entire contents of which are incorporated herein.REFERENCE SIGNS LIST

[0061] 10: Gypsum board (Product-use panel) 11: Wide surface (Front surface) 12: First edge 13: Second edge 15: Center region 18: Fastener (Head of fastener) 20, 20A, 20B: Design-pattern groove 20C: Design-pattern groove (Through-hole) 30, 30A, 30B, 30C, 30D, 30E, 30F, 30G: Fastening-pattern groove 35: Groove unit 40, 40A, 40B, 40C: Building-use panel 50: Mold 51: Press-forming surface 52: First edge 53: Second edge 55: Center region 60: Design-pattern protrusion 70: Fastening-pattern protrusion 75: Protrusion unit

Examples

Embodiment Construction

[0015]Hereinafter, a building-use panel production method, a mold, and a building-use panel according to the embodiments are described with reference to the appended drawings. In the specification and drawings, components that are substantially the same are denoted by the same reference numerals, and redundant description thereof is omitted in some cases.

[Mold, building-use panel production method, and building-use panel according to embodiments]

[0016]An example of a mold, a building-use panel production method, and a building-use panel according to the embodiments is described with reference to FIGS. 1 to 12. Here, FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment, whereas FIG. 2 is a plan view of an example of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. Also, FIG. 3 is an enlarged view of an example of design-pattern protrusio...

TECHNICAL FIELD

[0001] The present disclosure relates to a building-use panel production method, a mold, and a building-use panel.BACKGROUND ART

[0002] When a building-use panel is to be fastened to a ceiling base material or a wall base material by fasteners, on-site marking of multiple fastening positions is first performed on a wide surface of the building-use panel by using what is known as a sumi-dashi (ink marking) technique. However, such on-site marking on the building-use panel is labor-intensive, and this problem becomes more even pronounced when there are many building-use panels or when the wide surface of the building-use panel has a large surface area. Further, the pitch of multiple fastening positions may differ depending on the location and size of the building-use panel. Therefore, it is necessary to mark the fastening positions with these factors in mind, which also contributes to the complexity of on-site marking.

[0003] It is therefore possible to eliminate the complexity of the above-described on-site marking by adding fastening positions to the wide surface of the building-use panel in advance in a factory setting or a similar setting. In the factory setting or a similar setting, the fastening positions are generally added by a method for printing or marking fastening positions on a wide surface of a building-use panel.

[0004] Importantly, it is understood that in a case where a building-use panel is to be used as an interior finishing material or the like, and a design pattern is to be featured on a wide surface thereof, printing or marking the fastening positions requires both a step of forming the design pattern and a step of forming a fastening pattern that defines a fastening position of a fastener, and consequently the number of steps at the time of producing the building-use panel increases and production efficiency decreases.

[0005] Therefore, a building-use panel production method that can minimize the number of steps is desired, where both a design pattern and a fastening pattern that defines the fastening position of a fastener are formed on a wide surface.

[0006] Here, Patent Document (PTL) 1 proposes a method for producing a marked panel. The method for producing the marked panel includes a step of preparing a panel body having a front surface and a rear surface, and a step of adding in advance a plurality of markings, arranged at a predetermined pitch along a first direction parallel to the front surface and the rear surface, on at least one of the front surface or the rear surface of the panel body.CITATION LISTPATENT LITERATURE

[0007] PTL 1: Japanese Patent Application Laid-Open Publication No. 2018-154999SUMMARY OF THE INVENTIONTECHNICAL PROBLEM

[0008] Although the production method of the marked panel in PTL 1 is a production method in which the plurality of markings are added in advance at fastening positions of fasteners on the front surface or the rear surface of the panel body, this related-art patent document does not disclose a technique for addressing the aforementioned issue, namely, minimizing the number of steps when adding, on a wide surface of a building-use panel, both a design pattern and a fastening pattern that defines a fastening position of a fastener.

[0009] The present disclosure provides a building-use panel production method, a mold for use in this production method, and also a building-use panel produced by this production method, all of which are capable of minimizing the number of steps, where both a design pattern and a fastening pattern that defines a fastening position of a fastener are formed on a wide surface of the building-use panel.SOLUTION TO THE PROBLEM

[0010] In a building-use panel production method according to an aspect of the present disclosure, a plurality of design patterns and a plurality of fastening patterns that define positions of fasteners are formed at a same time on a wide surface that is a front surface of a building-use panel.

[0011] Also, a mold according to another aspect of the present disclosure for use when performing press-forming on one wide surface that is a front surface of a product-use panel obtained by cutting a base sheet for building-use panels into predetermined planar dimensions, includes, on a single pressing surface mold, a plurality of design-pattern protrusions for forming a plurality of design-pattern grooves in the wide surface and a plurality of fastening-pattern protrusions for forming a plurality of fastening-pattern grooves in the wide surface, the plurality of fastening-pattern grooves defining fastening positions of fasteners.

[0012] Further, a building-use panel according to another aspect of the present disclosure has a wide surface that is a front surface, wherein the wide surface is provided with a plurality of design-pattern grooves, and wherein a plurality of fastening-pattern grooves are provided at a predetermined pitch along the wide surface, the fastening-pattern grooves defining fastening positions of fasteners.ADVANTAGEOUS EFFECTS OF THE INVENTION

[0013] According to the present disclosure, the number of steps can be minimized where both the design pattern and the fastening pattern that defines the fastening position of the fastener are formed on the wide surface of the building-use panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] [FIG. 1] FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment. [FIG. 2] FIG. 2 is a plan view of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. [FIG. 3] FIG. 3 is an enlarged view of an example of design-pattern protrusions provided in a dispersed manner, and is an enlarged view of section III of FIG. 2. [FIG. 4] FIG. 4 is a plan view illustrating a state in which the design-pattern protrusion and a fastening-pattern protrusion are arranged side by side, and is an enlarged view of section IV of FIG. 2. [FIG. 5] FIG. 5 is a plan view of an example of a building-use panel according to an embodiment. [FIG. 6] FIG. 6 is an enlarged view of an example of design-pattern grooves arranged in a dispersed manner, and is an enlarged view of section VI of FIG. 5. [FIG. 7] FIG. 7 is a plan view illustrating a state in which a design-pattern protrusion and a fastening-pattern groove are arranged side by side, and is an enlarged view of section VII of FIG. 5. [FIG. 8] FIG. 8 is a plan view of other examples of the fastening-pattern groove. [FIG. 9] FIG. 9 is a plan view of another example of a building-use panel according to an embodiment. [FIG. 10] FIG. 10 is an enlarged view of an example of design-pattern protrusions arranged in a dispersed manner, and is an enlarged view of section X of FIG. 9. [FIG. 11] FIG. 11 is a plan view of yet another example of a building-use panel according to an embodiment. [FIG. 12] FIG. 12 is a perspective view of part of another example of a building-use panel according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, a building-use panel production method, a mold, and a building-use panel according to the embodiments are described with reference to the appended drawings. In the specification and drawings, components that are substantially the same are denoted by the same reference numerals, and redundant description thereof is omitted in some cases.[Mold, building-use panel production method, and building-use panel according to embodiments]

[0016] An example of a mold, a building-use panel production method, and a building-use panel according to the embodiments is described with reference to FIGS. 1 to 12. Here, FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment, whereas FIG. 2 is a plan view of an example of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. Also, FIG. 3 is an enlarged view of an example of design-pattern protrusions arranged in a dispersed manner, and is an enlarged view of section III of FIG. 2, whereas FIG. 4 is a plan view illustrating a state in which the design-pattern protrusion and a fastening-pattern protrusion are arranged side by side, and is an enlarged view of section IV of FIG. 2. FIG. 5 is a plan view of an example of a building-use panel according to an embodiment, FIG. 6 is an enlarged view of an example of design-pattern grooves arranged in a dispersed manner, and is an enlarged view of section VI of FIG. 5, whereas, FIG. 7 is a plan view illustrating a state in which a design-pattern groove and a fastening-pattern groove are arranged side by side, and is an enlarged view of section VII of FIG. 5.

[0017] A mold 50 for use in a building-use panel production method is a mold that is for use when forming a design-pattern groove and a fastening-pattern groove in the wide surface 11, during press-forming, by press-forming with the press-forming surface 51 in the X direction, on one wide surface 11 that is the front surface of a product-use panel 10 obtained by cutting a base sheet for building-use panels into predetermined planar dimensions.

[0018] Examples of the product-use panel 10 that is to be subjected to a press-forming step include a gypsum plate, a gypsum board, a calcium silicate board, a particle board, a hardboard, plywood, structural plywood, and the like, but the product-use panel 10 in the illustrated examples is a gypsum board. Also, in addition to a general gypsum board, the gypsum board includes a reinforced gypsum board, an ordinary hard gypsum board, a sheathing hard gypsum board, a moisture absorptive and desorptive reinforced gypsum board, a moisture absorptive and desorptive ordinary gypsum board, a moisture absorptive and desorptive sheathing hard gypsum board, a gypsum plate with a glass fiber nonwoven fabric, a glass mat gypsum board, and the like.

[0019] The gypsum board 10 is a rectangularly-shaped board in plan view in which both wide surfaces of the gypsum board core material are covered with gypsum board liner paper. The planar dimensions of t1 × t2 are set to be, for example, 910 mm × 455 mm, 910 mm × 910 mm, 1,000 mm × 1,000 mm, or 1,000 mm × 500 mm. The thickness of the gypsum board 10 is, for example, 9.5 mm or 12.5 mm. The gypsum board 10 is formed by cutting a base sheet (not illustrated) having planar dimensions of, for example, 1,854 mm × 945 mm into the desired planar dimensions as described above.

[0020] As illustrated in FIG. 2, the press-forming surface 51 of the mold 50 is provided with numerous design-pattern protrusions 60 in a dispersed manner.

[0021] As illustrated in FIG. 3, the design pattern of the numerous design-pattern protrusions 60 is a travertine pattern. That is, as illustrated in FIG. 5, numerous design-pattern grooves 20 exhibiting a travertine pattern are added in a dispersed manner in the wide surface 11 of the gypsum board 10 which is press-formed by the mold 50 having the press-forming surface 51 of the illustrated example. The travertine pattern is also referred to in Japanese as a "bug-eaten pattern", due to its irregular, porous appearance.

[0022] Referring back to FIG. 2, the press-forming surface 51 of the mold 50 has first edges 52 extending along a first direction (horizontal direction in FIG. 2) and second edges 53 extending along a second direction (vertical direction in FIG. 2), forming a rectangular shape in plan view, and a plurality of fastening-pattern protrusions 70 are provided at a predetermined first pitch t3 in straight lines parallel and adjacent to the pair of the first edges 52 among these four edges.

[0023] Also, on the press-forming surface 51, a plurality of fastening-pattern protrusions 70 are provided at a predetermined second pitch t7 in a straight line, in a center region 55, the straight line of the plurality of fastening-pattern protrusions 70 being parallel to the first edges 52.

[0024] As illustrated in FIG. 5, the fastening-pattern protrusions 70 are protrusions for adding, in the wide surface 11 of a building-use panel 40, fastening-pattern grooves 30 that define the fastening positions of fasteners. The building-use panel 40 is fastened by a plurality of non-illustrated fasteners to a non-illustrated ceiling base material or a non-illustrated wall base material. Examples of the fasteners include screws, nails, staples, and the like.

[0025] Referring back to FIG. 2, the first pitch t3 is set to be 150 mm or less than 150 mm, for example, and the second pitch t7 is set to be 200 mm or less than 200 mm, for example. The spacing of the fasteners is preferably set to be a minimum of 50 mm and a maximum of 606 mm, although the spacing varies depending on whether the fasteners are used to fasten the building-use panel forming either the ceiling or wall, and whether the building-use panel is a single sheet or multiple sheets.

[0026] In FIG. 2, length t4 from the second edge 53 to the first fastening-pattern protrusion 70 can be set to be 15 mm, for example, and likewise, length t6 from the first edge 52 to the fastening-pattern protrusion 70 can be set to be 15 mm, for example. In the illustrated example, a plurality of fastening-pattern protrusions 70 in the center region 55 are set to be located at a distance t5 from the first edges 52, t5 being half the length of t2 on the second edges 53.

[0027] As illustrated in FIG. 4, the fastening-pattern protrusions 70 are protrusions that are circular in shape in plan view (including elliptical shape in plan view), whereas the design-pattern protrusions 60 are protrusions designed to replicate a travertine pattern. Therefore, the fastening-pattern grooves 30 formed by the engagement of the fastening-pattern protrusions 70 with the wide surface 11 of the building-use panel 40 are circular grooves in plan view, as illustrated in FIGS. 5 and 7.

[0028] In the illustrated examples, the design-pattern protrusion 60 is arranged adjacent to the fastening-pattern protrusion 70 that is circular in shape in plan view. As illustrated in FIG. 2 and FIG. 4, the design-pattern protrusions 60 are arranged adjacent to each of the fastening-pattern protrusions 70 provided on the press-forming surface 51, and the design-pattern protrusion 60 and fastening-pattern protrusion 70 arranged in a side-by-side manner together form a protrusion unit 75.

[0029] Therefore, the design-pattern grooves 20 formed by the engagement of the design-pattern protrusion 60, in the illustrated example, with the wide surface 11 of the building-use panel 40 are grooves fashioned to replicate a travertine pattern as illustrated in FIGS. 5 and 7.

[0030] Thus, the mold 50 illustrated in FIG. 2 includes, on a single press-forming surface 51 mold 50, a plurality of design-pattern protrusions 60 for forming, in the wide surface 11 of the building-use panel 40, the plurality of design-pattern grooves 20, and the plurality of fastening-pattern protrusions 70 for forming, in the wide surface 11, the plurality of fastening-pattern grooves 30 that define the fastening positions of the fasteners.

[0031] Therefore, when press-forming is performed once on the wide surface 11 of the gypsum board 10 using the mold 50, the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 are formed in the wide surface 11 of the gypsum board 10 at the same time. This mold 50 enables a more efficient building-use panel production method, as it reduces the number of steps required compared to another production method of a building-use panel in which design-pattern grooves 20 and fastening-pattern grooves 30 are formed in separate steps.

[0032] Next, an overview of an example of the building-use panel production method with use of the mold 50 is presented below. First, when the building-use panel 40 illustrated in FIG. 5 is to be produced, the base sheet of the gypsum board (not illustrated) is cut into predetermined planar dimensions to produce the product-use panel 10. The product-use panel 10 is rectangular in shape in plan view, and its planar dimensions are 910 mm × 455 mm, 910 mm × 910 mm, or the like (This is the cutting step.) as described above.

[0033] Next, the mold 50 is used on one wide surface 11 that is the front surface of the product-use panel 10, and press-forming is performed to form the plurality of design-pattern grooves 20 (an example of a design pattern) and the plurality of fastening-pattern grooves 30 (an example of a fastening pattern) at the same time (This is the press-forming step).

[0034] Next, the wide surface 11 that is the front surface of the product-use panel 10 in which the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 have been formed, is surface finished by applying a coating to the wide surface 11 and drying the coating, resulting in the building-use panel 40 illustrated in FIG. 5. A roller coater or the like is used for performing the coating, and a dryer or the like is used for performing drying (This is the coating step).

[0035] By performing this coating step, the wide surface 11 of the building-use panel 40 is colored white or ivory, for example, whereas the design-pattern grooves 20 and the fastening-pattern grooves 30 are not colored, and the gray-colored liner paper with which the gypsum board 10 is equipped is exposed (the liner paper is pushed in towards the rear surface side by the design-pattern protrusions 60 and the fastening-pattern protrusions 70 of the mold 50). Therefore, the contrast between: the design-pattern grooves 20 and the fastening-pattern grooves 30; and the colored wide surface 11 gives a unique appearance design.

[0036] Further, following the coating step, a chamfering step of chamfering the edges of all four sides of the building-use panel may be performed.

[0037] As illustrated in FIG. 5, since the press-forming surface 51 is provided with the protrusion unit 75, a groove unit 35 made up of the fastening-pattern groove 30 and the design-pattern groove 20 that is adjacent thereto is formed at the fastening position of the fastener in the wide surface 11 of the building-use panel 40, and a plurality of the groove units 35 are arranged orderly at the first pitch t1 and the second pitch t2. In addition, as illustrated in FIGS. 5 and 6, numerous design-pattern grooves 20 exhibiting the travertine pattern are dispersed in all regions of the wide surface 11.

[0038] Since the fastening-pattern groove 30 and the design-pattern grooves 20 adjacent thereto form one groove unit 35, it is easier for workers to find each fastening-pattern groove 30 than when the fastening-pattern groove 30 circular in shape in plan view is provided alone.

[0039] Furthermore, since the design-pattern groove 20 forming the groove unit 35 is the same design-pattern groove as the design-pattern grooves 20 of the travertine pattern provided in a dispersed manner, the design-pattern groove 20 included in the groove unit 35 does not detract from the exterior design quality of the building-use panel 40. It is to be noted that the fastening-pattern groove 30 is easier to find when performing fastening if the pattern groove 30 has a design characteristic different from that of the design-pattern groove 20 having a travertine pattern provided in a dispersed manner but this may detract from the design uniformity of the building-use panel 40. Therefore, it is preferable to set the pattern of the fastening-pattern groove 30 in consideration of both factors.

[0040] As illustrated in FIG. 7, the planar dimensions of the fastening-pattern groove 30 circular in shape in plan view is set to be less than or equal to the size of the head of the fastener 18 illustrated by the solid line. In the illustrated examples, the planar dimensions of the fastening-pattern groove 30 are set to be smaller than the sizes of the heads of the fastener 18. Therefore, when the fastener 18 is driven into the fastening-pattern groove 30, the fastening-pattern groove 30 is covered by the head of the fastener 18, and the fastening-pattern groove 30 is unlikely to be seen from the outside. This makes it possible to mitigate degradation in the exterior design quality of the finished surface, such as a loss of the design uniformity of the building-use panel 40 caused by the fastening-pattern grooves 30 being visible from the outside.

[0041] According to the building-use panel production method illustrated in the drawings, by applying the mold 50 to the wide surface 11 of the gypsum board 10 and performing press-forming, the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 can be formed in the wide surface 11 at the same time. This enables a more efficient building-use panel production method, as it reduces the number of steps required compared to another production method of a building-use panel in which design-pattern grooves 20 and fastening-pattern grooves 30 are formed in separate steps.

[0042] The building-use panel 40, in which design-pattern grooves 20 of a plurality of travertine patterns are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30 are provided at a predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30 are provided on Gyptone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0043] Here, FIG. 8 illustrates other examples of the fastening patterns of the fastening pattern groove. The examples illustrated in (a) to (g) in FIG. 8 are, in order, a cross-shaped fastening-pattern groove 30A, an X-shaped fastening-pattern groove 30B, a triangle-shaped (an example of polygonal) fastening-pattern groove 30C, an asterisk-shaped (an example of a special symbol) fastening-pattern groove 30D, an exclamation mark-shaped (another example of a special symbol) fastening-pattern groove 30E, a question mark-shaped (another example of a special symbol) fastening-pattern groove 30F, and a star-shaped (another example of a special symbol) fastening-pattern groove 30G.

[0044] Since fastening-pattern protrusions having shapes complementary to these fastening-pattern grooves are provided on the press-forming surface of the mold, various fastening grooves can be formed in the wide surface 11 of the gypsum board 10. As for these various shapes of fastening-pattern grooves, as illustrated in FIG. 5, a single-type of fastening pattern groove may be provided in the wide surface 11, or multiple types of fastening-pattern grooves may be provided in the wide surface 11. Various fastening pattern shapes other than those illustrated in the drawings may be used.

[0045] Thus far, the building-use panel production method in which the plurality of design-pattern grooves 20 and the plurality of fastening-pattern grooves 30 in the wide surface 11 of the gypsum board 10 are formed at the same time, has been described using the mold 50. However, as another example of the building-use panel production method of the embodiment, there is also a method for forming the plurality of design patterns and the plurality of fastening patterns at the same time through printing.

[0046] More specifically, there are three possible methods of forming the plurality of design patterns and the plurality of fastening patterns at the same time through printing. One of the methods is to produce a gypsum board using a liner paper for the gypsum board on which a plurality of design patterns and a plurality of fastening patterns are printed in advance, and then cut the gypsum board into predetermined product dimensions. Another method is a forming (printing) method (printing step) in which, during the production of the gypsum board, an unillustrated transfer roll or the like bearing a design-pattern display (another example of the design pattern) and a fastening-pattern display (another example of the fastening pattern) is used to form (print) both pattern displays on a front surface of the board at the same time. Yet another method is a forming (printing) method in which: laminate paper on which a plurality of design patterns and a plurality of fastening patterns are printed in advance is laminated onto the base sheet for building-use panels or onto the product-use panel obtained by cutting the base sheet for building-use panels into predetermined planar dimensions; or an unillustrated transfer roll or the like bearing a design-pattern display (another example of the design pattern) and a fastening-pattern display (another example of the fastening pattern) is used to form (print), at the same time, both pattern displays on a surface of the base sheet for building-use panels or on the product-use panel obtained by cutting the base sheet for building-use panels into predetermined planar dimensions.

[0047] In this way, even with a display (marking) in which both the design pattern and the fastening pattern are printed, by printing both patterns on the base sheet for building-use panels or on the wide surface of the product-use panel at the same time, the number of steps can be minimized, and thus this technique serves as a highly efficient building-use panel production method.

[0048] Next, another example of the building-use panel is described with reference to FIG. 9 and FIG. 10. Here, FIG. 9 is a plan view of another example of a building-use panel according to an embodiment, whereas FIG. 10 is an enlarged view of section X of FIG. 9 and is an enlarged view of another example of the design-pattern grooves arranged in a dispersed manner.

[0049] A building-use panel 40A differs from the building-use panel 40 in that it has the design-pattern grooves 20A featuring the marble pattern instead of the design-pattern grooves 20 with the travertine pattern, and also has star-shaped fastening-pattern grooves 30G, which are special symbols. Here, a form other than the fastening-pattern grooves 30G in the illustrated example may be used as the fastening-pattern grooves.

[0050] The building-use panel 40A, in which a plurality of design-pattern grooves 20A featuring a marble pattern are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30G are provided at pitches t3 and t7 in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30G are provided on Marbletone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0051] Next, yet another example of a building-use panel is described with reference to FIG. 11. Here, FIG. 11 is a plan view of yet another example of a building-use panel according to an embodiment.

[0052] A building-use panel 40B differs from the building-use panels 40 and 40A in that it has star-shaped (an example of a pictorial pattern) design-pattern grooves 20B instead of the design-pattern grooves 20 and 20A featuring the travertine pattern and the marble pattern, respectively, and that it has triangle-shaped fastening-pattern grooves 30C which are different from the star-shaped fastening-pattern grooves 30, 30G. Here, a form other than the fastening-pattern grooves 30C in the illustrated example may be used as the fastening-pattern grooves.

[0053] The building-use panel 40B, in which a plurality of star-shaped design-pattern grooves 20B are provided in a dispersed manner and, further, a plurality of fastening-pattern grooves 30C are provided at a predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30C are provided on Stellart (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0054] Next, yet another example of a building-use panel is described with reference to FIG. 12. Here, FIG. 12 is a perspective view of part of another example of a building-use panel according to an embodiment.

[0055] A building-use panel 40C is different from the building-use panels 40, 40A, and 40B in that it has a plurality of design-pattern grooves 20C that are through-holes instead of grooves that extend to a position within the gypsum board 10 thickness-wise. Although the cross-shaped fastening-pattern groove 30A is provided at a predetermined pitch, an aspect other than the fastening-pattern grooves 30A in the illustrated example may be used as the fastening-pattern grooves.

[0056] The plurality of through-holes 20C in the illustrated example are provided so as to be arranged in the wide surface 11 in an orderly manner (arranged with multiple grid points) at a predetermined pitch t8 in the vertical and horizontal directions. Here, the pitch t8 can be set to be approximately 22 mm, for example.

[0057] The building-use panel 40C provided with the plurality of through-holes 20C forms a perforated acoustic panel, and the plurality of through-holes 20C serve as design grooves that provide both sound-absorbing and aesthetic functions. As described, the building-use panel 40C, in which the plurality of through-holes 20C are provided in an orderly manner and, further, the plurality of fastening-pattern grooves 30A are provided at the predetermined pitch in the wide surface 11, serves as a product in which the plurality of fastening-pattern grooves 30A are provided on Tiger Tone (Registered trademark) made by Yoshino Gypsum Co., Ltd.

[0058] Here, in a production method in which the plurality of through-holes 20C and the plurality of fastening-pattern grooves 30A are formed in the wide surface 11 at the same time, a mold is used that has a press-forming surface with a plurality of design-pattern protrusions and a plurality of fastening-pattern protrusions, the design-pattern protrusions and the plurality of fastening-pattern protrusions being of different heights (protrusion lengths).

[0059] Other embodiments, such as those in which other components are combined with the above configurations, are also possible, and the present disclosure is not limited to the configurations illustrated here by any means. In this respect, the configurations of the present disclosure may be changed without departing from the purpose of the present disclosure, and the configurations can be appropriately determined according to the usage form.

[0060] This international application claims priority based on Japanese Patent Application No. 2023-129053, filed on August 8, 2023, the entire contents of which are incorporated herein.REFERENCE SIGNS LIST

[0061] 10: Gypsum board (Product-use panel) 11: Wide surface (Front surface) 12: First edge 13: Second edge 15: Center region 18: Fastener (Head of fastener) 20, 20A, 20B: Design-pattern groove 20C: Design-pattern groove (Through-hole) 30, 30A, 30B, 30C, 30D, 30E, 30F, 30G: Fastening-pattern groove 35: Groove unit 40, 40A, 40B, 40C: Building-use panel 50: Mold 51: Press-forming surface 52: First edge 53: Second edge 55: Center region 60: Design-pattern protrusion 70: Fastening-pattern protrusion 75: Protrusion unit

Examples

Embodiment Construction

[0015]Hereinafter, a building-use panel production method, a mold, and a building-use panel according to the embodiments are described with reference to the appended drawings. In the specification and drawings, components that are substantially the same are denoted by the same reference numerals, and redundant description thereof is omitted in some cases.

[Mold, building-use panel production method, and building-use panel according to embodiments]

[0016]An example of a mold, a building-use panel production method, and a building-use panel according to the embodiments is described with reference to FIGS. 1 to 12. Here, FIG. 1 is a drawing for describing an example of a mold according to an embodiment and an example of a building-use panel production method according to an embodiment, whereas FIG. 2 is a plan view of an example of a press-forming surface of the mold as seen in the direction of arrow II in FIG. 1. Also, FIG. 3 is an enlarged view of an example of design-pattern protrusio...

Claims

1. A building-use panel production method, wherein both a plurality of design patterns and a plurality of fastening patterns that define positions of fasteners are formed at a same time on a wide surface that is a front surface of a building-use panel.

2. The building-use panel production method according to claim 1, comprising: a cutting step of cutting a base sheet for building-use panels into predetermined planar dimensions to produce a product-use panel; and a press-forming step of forming, by press-forming, both a design-pattern groove included in the design pattern and a fastening-pattern groove included in the fastening pattern at a same time in one wide surface that is a front surface of the product-use panel.

3. The building-use panel production method according to claim 2, further comprising: a coating step of applying a coating to the front surface of the product-use panel in which the design-pattern groove and the fastening-pattern groove have been formed, and drying the coating.

4. The building-use panel production method according to claim 1, comprising: a printing step of printing, at a same time, both a design-pattern display included in the design pattern and a fastening-pattern display included in the fastening pattern on a base sheet for building-use panels or on one wide surface that is a front surface of a product-use panel obtained by cutting the base sheet for building-use panels into predetermined planar dimensions.

5. A mold for use when performing press-forming on one wide surface that is a front surface of a product-use panel obtained by cutting a base sheet for building-use panels into predetermined planar dimensions, the mold comprising: on a single pressing surface mold, a plurality of design-pattern protrusions for forming a plurality of design-pattern grooves in the wide surface and; a plurality of fastening-pattern protrusions for forming a plurality of fastening-pattern grooves in the wide surface, the plurality of fastening-pattern grooves defining fastening positions of fasteners.

6. A building-use panel having a wide surface that is a front surface, wherein the wide surface is provided with a plurality of design-pattern grooves, and wherein a plurality of fastening-pattern grooves are provided at a predetermined pitch along the wide surface, the fastening-pattern grooves defining fastening positions of fasteners.

7. The building-use panel according to claim 6, wherein planar dimensions of the fastening-pattern grooves are set to be less than or equal to planar dimensions of heads of the fasteners.

8. The building-use panel according to claim 6, wherein the design-pattern grooves and the fastening-pattern grooves are arranged orderly at the fastening positions of the fasteners.

9. The building-use panel according to claim 6, wherein the design-pattern grooves are through-holes.

10. The building-use panel according to claim 6, wherein a design pattern of the design-pattern grooves is a travertine pattern, a marble pattern, or a pictorial pattern.

11. The building-use panel according to claim 6, wherein the fastening-pattern grooves each have a shape in plan view that is any one of circular, cross-shaped, X-shaped, polygonal, or a special symbol.

12. The building-use panel according to claim 6, wherein the building-use panel has a shape in plan view that is rectangular having first edges extending along a first direction and second edges extending along a second direction, the first edges and the second edges being perpendicular to each other, and wherein the plurality of fastening-pattern grooves are provided at a predetermined first pitch in straight lines parallel and adjacent to the first edges.

13. The building-use panel according to claim 12, wherein, on the wide surface of the building-use panel, a plurality of the fastening patterns are provided at a predetermined second pitch in a straight line in a center region away from the first edges, the straight line of the plurality of the fastening patterns being parallel to the first edges.

14. The building-use panel according to claim 6, wherein the building-use panel is formed by a gypsum board.

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