Fiberboard structure manufacturing method, fiberboard structure manufacturing system, and fiberboard structure

Abstract

To provide a fiberboard structure manufacturing method, a fiberboard structure manufacturing system, and a fiberboard structure, which achieve favorable inkjet-based printing on a substrate to which a fiberboard is applied.SOLUTION: A fiberboard structure manufacturing method comprises: applying an aqueous sealer to a first surface of a substrate in which a fiberboard is used (S10); forming, on the first surface, an undercoat layer in which the aqueous sealer is dried (S12); applying, to the first surface on which the undercoat layer is formed, an aqueous preconditioning liquid having a function of thickening an aqueous ink (S14); and jetting the aqueous ink from an inkjet-based jetting head to apply the aqueous ink to the first surface on which the aqueous preconditioning liquid is applied (S18).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a fiberboard structure, a fiberboard structure manufacturing system, and a fiberboard structure.

Background Art

[0002] In recent years, inkjet printers have been used with various types of materials on substrates. Examples of substrate materials include wood fiberboards such as MDF. MDF is an abbreviation of the English term Medium Density Fiberboard, which represents medium-density fiberboard.

[0003] When applying the inkjet method to print on a fiberboard such as MDF, the fiberboard strongly absorbs the ink, and no ink remains on the surface of the fiberboard. As a result, there are problems such as color degradation compared to the case of printing on a substrate such as paper. Techniques for preventing the ink from soaking into the fiberboard are disclosed in each of Patent Documents 1 to 3 shown below.

[0004] Patent Document 1 describes an inkjet recording apparatus that switches the ink used according to the type of recording medium to be recorded. The apparatus described in the document performs recording using a pigment-based ink, a clear emulsion ink, and a reaction liquid when recording on a low-permeability recording medium for outdoor display.

[0005] Patent Document 2 describes a printing method in which an aqueous coating liquid is landed on a substrate, and an aqueous colored ink is landed on the coating liquid to form a printing layer. Wood and the like are described as substrates applicable to the printing method in the document.

[0006] Patent Document 3 describes an inkjet recording method for building material printing. The method described in the document includes a pretreatment step of forming a primer layer on the printing surface of the building material in advance. The primer layer suppresses the penetration of the ink into the building material and improves the adhesion of the ink.

Prior Art Documents

Patent Document

[0007]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0008] However, in the methods described in Patent Document 1 to Patent Document 3, there is a problem that the reaction solution or the like described in Patent Document 1 is absorbed by the fiber board, and it is difficult to leave ink on the ink-coated surface of the fiber board.

[0009] The present invention has been made in view of such circumstances, and an object thereof is to provide a method for manufacturing a fiber board structure, a fiber board structure manufacturing system, and a fiber board structure in which preferable printing by an inkjet method on a base material to which a fiber board is applied is realized.

Means for Solving the Problems

[0010] The method for manufacturing a fiber board structure according to the first aspect of the present disclosure forms an undercoat layer obtained by drying an aqueous sealer applied to a first surface of a base material on which a fiber board is used on the first surface, and applies an aqueous preconditioning liquid having a function of thickening the aqueous ink to the first surface on which the undercoat layer is formed, discharges the aqueous ink from a discharge head of an inkjet method, and applies the aqueous ink to the first surface on which the aqueous preconditioning liquid is applied.

[0011] According to the method for manufacturing a fiberboard structure according to the first aspect of the present disclosure, a conditioning liquid is applied to the first surface of a base material coated with an aqueous sealer. Thereby, the penetration of the conditioning liquid into the base material is suppressed, and a specified amount of the conditioning liquid remains on the first surface of the base material.

[0012] Further, droplets of aqueous ink are applied to the first surface of the base material on which the conditioning liquid remains. Thereby, the ink droplets landing on the conditioning liquid thicken, and the movement of the droplets of the aqueous ink landing on the first surface of the base material is suppressed.

[0013] The method for manufacturing a fiberboard structure according to the second aspect is the method for manufacturing a fiberboard structure according to the first aspect, wherein the aqueous sealer and the aqueous ink may contain the same type of resin.

[0014] According to such an aspect, the adhesion between the undercoat layer obtained by drying the aqueous sealer and the aqueous ink can be relatively improved.

[0015] The method for manufacturing a fiberboard structure according to the third aspect is the method for manufacturing a fiberboard structure according to the first aspect or the second aspect, wherein the aqueous sealer may be applied thicker than the aqueous ink.

[0016] According to such an aspect, the penetration of the aqueous ink into the base material is suppressed.

[0017] The method for manufacturing a fiberboard structure according to the fourth aspect is the method for manufacturing a fiberboard structure according to any one of the first aspect to the third aspect, wherein the aqueous sealer may contain white colorant particles.

[0018] According to such an aspect, even if the first surface of the base material is a color other than white, a white base is formed on the first surface of the base material without using white ink.

[0019] The method for manufacturing a fiberboard structure according to the fifth aspect is the method for manufacturing a fiberboard structure according to any one of the first to fourth aspects, wherein the aqueous ink includes a white ink containing white colorant particles, and the application of the aqueous ink may be performed by applying the white ink to the first surface to which the aqueous preconditioning liquid has been applied.

[0020] According to such an aspect, even if the first surface of the base material is a color other than white, a white base is formed on the first surface of the base material.

[0021] The method for manufacturing a fiberboard structure according to the sixth aspect is the method for manufacturing a fiberboard structure according to any one of the first to fifth aspects, wherein a coating liquid may be applied to the first surface to which the aqueous ink has been applied.

[0022] According to such an aspect, the abrasion resistance of the image printed using the aqueous ink can be relatively improved.

[0023] The coating liquid applied to the first surface of the base material may be dried.

[0024] The method for manufacturing a fiberboard structure according to the seventh aspect is the method for manufacturing a fiberboard structure according to the sixth aspect, wherein the application of the coating liquid may be performed by applying a non-contact process.

[0025] According to such an aspect, contact with the aqueous ink when the coating liquid is applied to the first surface of the base material is avoided.

[0026] The method for manufacturing a fiberboard structure according to the eighth aspect is the method for manufacturing a fiberboard structure according to any one of the first to seventh aspects, wherein a moisture-proof layer may be formed on the second surface opposite to the first surface of the base material.

[0027] According to such an aspect, penetration of moisture from the second surface into the base material is suppressed, and deterioration of the base material due to penetration of moisture can be suppressed.

[0028] The method for manufacturing a fiberboard structure according to the ninth aspect may be the method for manufacturing a fiberboard structure according to any one of the first to eighth aspects, in which a sanding process may be performed on the first surface of the base material.

[0029] According to such an aspect, an aqueous sealer can be uniformly applied to the first surface of the base material.

[0030] The method for manufacturing a fiberboard structure according to the tenth aspect may be the method for manufacturing a fiberboard structure according to any one of the first to ninth aspects, in which the aqueous sealer applied to the first surface of the base material is dried to form a primer layer on the first surface of the base material.

[0031] According to such an aspect, a primer layer can be formed from the aqueous sealer.

[0032] The method for manufacturing a fiberboard structure according to the eleventh aspect may be the method for manufacturing a fiberboard structure according to any one of the first to tenth aspects, in which a sanding process may be performed on the primer layer formed on the first surface of the base material.

[0033] According to such an aspect, a preconditioning liquid and an aqueous ink can be uniformly applied to the primer layer.

[0034] The fiberboard structure manufacturing system according to the twelfth aspect of the present disclosure includes a sealer coating device that applies an aqueous sealer to the first surface of a base material to which a fiberboard is applied, and a preconditioning liquid coating device that applies an aqueous preconditioning liquid having a function of thickening the aqueous ink to the first surface on which a primer layer is formed by drying the aqueous sealer, and an inkjet type discharge head that discharges the aqueous ink and applies the aqueous ink to the first surface to which the aqueous preconditioning liquid is applied.

[0035] According to the fiberboard structure manufacturing system according to the 12th aspect of the present disclosure, it is possible to obtain the same operational effects as the fiberboard structure manufacturing method according to the 1st aspect of the present disclosure. The constituent elements of the fiberboard structure manufacturing methods according to the 2nd to 11th aspects can be applied to the constituent elements of the fiberboard structure manufacturing systems according to other aspects.

[0036] The fiberboard structure according to the 13th aspect of the present disclosure includes a base material to which a fiberboard is applied, an undercoat layer obtained by drying an aqueous sealer applied to the first surface of the base material, and an ink layer thickened by reacting with an aqueous ink applied to an aqueous conditioning liquid applied to the undercoat layer, the aqueous conditioning liquid having a function of thickening the aqueous ink.

[0037] According to the fiberboard structure according to the 13th aspect of the present disclosure, it is possible to obtain the same operational effects as the fiberboard structure manufacturing method according to the 1st aspect of the present disclosure. The constituent elements of the fiberboard structure manufacturing methods according to the 2nd to 11th aspects can be applied to the constituent elements of the fiberboard structures according to other aspects.

Effects of the Invention

[0038] According to the present invention, a conditioning liquid is applied to the first surface of a base material to which an aqueous sealer is applied. Thereby, the penetration of the conditioning liquid into the base material is suppressed, and a specified amount of the conditioning liquid remains on the first surface of the base material.

[0039] Further, droplets of aqueous ink are applied to the first surface of the base material on which the conditioning liquid remains. Thereby, the ink droplets landing on the conditioning liquid thicken, and the movement of the droplets of aqueous ink landing on the first surface of the base material is suppressed.

Brief Description of the Drawings

[0040]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0041] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In this specification, the same reference numerals are assigned to the same components, and overlapping descriptions are omitted as appropriate. Further, when a plurality of components are exemplified in the following embodiments, it can be interpreted as including at least one of the plurality of components.

[0042] [Method for Manufacturing Fiberboard Structure] FIG. 1 is a flowchart showing the procedure of a method for manufacturing a fiberboard structure according to an embodiment. Hereinafter, as a base material of the fiberboard structure, a wood fiberboard such as a medium density fiberboard is exemplified. The medium density fiberboard is manufactured using wood fibers compressed with an adhesive as a material. Since the medium density fiberboard is manufactured using waste materials and residual materials as materials, its environmental suitability is relatively high.

[0043] In the embodiments shown below, a fiberboard is exemplified as the base material of the fiberboard structure. However, the material of the fiberboard is not limited to wood, and natural fibers collected from plants, animals, and minerals may be used, or artificial fibers such as chemical fibers may be used.

[0044] The chemical fiber may be an inorganic fiber or an organic fiber. Examples of inorganic fibers include metal fibers, glass fibers, carbon fibers, and rock fibers. Examples of organic fibers include synthetic fibers such as nylon, vinylon, and Kepler, semi-synthetic fibers, rayon, and recycled fibers such as PET. Note that PET is an abbreviation for PolyEthylene Terephthalate.

[0045] In the aqueous sealer coating step S10 illustrated in FIG. 1, a sealer coating device is used, and an aqueous sealer is applied to the printed surface of the base material to which the wood fiberboard is applied. The printed surface of the base material may be one surface of the base material or the other surface. That is, the printed surface of the base material may be at least either one of one surface and the other surface of the base material. Note that the base material to which the wood fiberboard is applied is denoted by reference sign S and illustrated in FIG. 9 and the like. Also, the printed surface of the base material is denoted by reference sign PF and illustrated in FIG. 9 and the like.

[0046] Before the aqueous sealer coating step S10 is performed, the base material to which the wood fiberboard is applied may be subjected to sanding treatment on the printed surface, and at least a part of the fuzz on the printed surface may be removed. For the sanding treatment on the printed surface, a sanding machine may be applied, or it may be a manual sanding treatment.

[0047] The base material subjected to the sanding treatment on the printed surface may be subjected to a treatment for removing dust and the like on the printed surface. For the treatment for removing dust and the like on the printed surface, methods such as suction, blowing of gas, and wiping may be applied.

[0048] The water-based sealer is applied to the entire printed surface of the substrate. The water-based sealer functions as a primer layer on the printed surface of the substrate. The water-based sealer may contain resin particles such as acrylic resin and urethane resin.

[0049] The water-based sealer may disperse pigment particles such as titanium oxide that function as white coloring material particles. Thereby, a white base can be formed on the printed surface of the substrate.

[0050] The coating amount of the water-based sealer in the liquid state before the drying treatment may be applied with the mass per unit area. For example, the coating amount of the water-based sealer in the liquid state before the drying treatment may be 0.1 grams per square meter or more and 1000 grams per square meter or less. The coating amount of the water-based sealer in the liquid state before the drying treatment is preferably 10 grams per square meter or more, and more preferably 100 grams per square meter or more. Note that grams per square meter can be referred to as gsm, which is an abbreviation of the English notation Grams per Square Meter.

[0051] Examples of the water-based sealer include the water-based sanding sealer manufactured by Asahi Pen Co., Ltd., the water-based sanding sealer manufactured by Wako Paint Co., Ltd., and the water-based primer sealer for wood parts manufactured by Nippon Paint Co., Ltd.

[0052] The water-based sealer is a material such as the above-mentioned sanding sealer, and can include all materials used for the treatment of the substrate before the main coating is performed. Also, the water-based sealer may dissolve or disperse the above-mentioned materials as solutes in a solvent mainly composed of water.

[0053] The water-based sealer coating step S10 may include a coating condition setting step. Before executing the water-based sealer coating step S10, the coating condition setting step may be executed. The coating conditions of the water-based sealer may include the type of the substrate, the type of the water-based sealer, and the coating amount of the water-based sealer. After the water-based sealer coating step S10, it proceeds to the water-based sealer drying step S12.

[0054] In the water-based sealer drying step S12, a sealer drying device is used, and a drying process is performed on the water-based sealer applied to the printed surface of the substrate. In the water-based sealer drying step S12, a mode in which the substrate coated with the water-based sealer is stored in a room temperature environment may be applied. As the room temperature, a temperature of 20°C or higher and 25°C or lower may be applied. Also, the processing time may be 1 hour or longer. The upper limit of the processing time may be defined from the perspective of productivity.

[0055] In the water-based sealer drying step S12, the substrate coated with the water-based sealer may be stored in an environment at a high temperature compared to the room temperature environment, and the productivity may be relatively improved. As the high temperature, a temperature exceeding 25°C such as 50°C or higher may be applied. The upper limit temperature of the high temperature may be defined according to the durability of the substrate. In the water-based sealer drying step S12, blowing may be applied, and heating and blowing may be appropriately combined.

[0056] The water-based sealer drying step S12 may include a drying condition setting step. Before the execution of the water-based sealer drying step S12, the drying condition setting step may be executed. The drying conditions of the water-based sealer may include the processing temperature and the processing time, etc. After the water-based sealer drying step S12, it proceeds to the sanding step S13.

[0057] In the sanding step S13, a sanding device is used, and a sanding process is performed on the undercoat layer which is the dried water-based sealer. The sanding process on the undercoat layer can remove the fuzz on the printed surface of the substrate generated by the penetration of the water-based sealer into the substrate. Also, the sanding process on the undercoat layer smooths the undercoat layer.

[0058] The water-based sealer coating step S10, the water-based sealer drying step S12, and the sanding step S13 may be repeatedly executed two or more times. In particular, when it is desired to relatively increase the glossiness on the printed surface of the substrate, the application, drying, and sanding of the water-based sealer may be repeatedly executed a plurality of times.

[0059] After the sanding process on the undercoat layer, the smoothness of the printing surface of the substrate may be measured. Coating, drying, and sanding of the water-based sealer may be repeatedly performed multiple times until the specified smoothness is achieved. Surface roughness may be applied as an index of smoothness.

[0060] The water-based sealer coating step S10, the water-based sealer drying step S12, and the sanding step S13 illustrated in FIG. 1 are grasped as steps included in the pre-preparation method of the substrate. After the pre-preparation of the substrate is completed, the process proceeds to the preconditioning liquid coating step S14.

[0061] In the preconditioning liquid coating step S14, a preconditioning liquid coating apparatus is used, and a water-based preconditioning liquid is applied to the printing surface of the substrate on which the undercoat layer obtained by drying the water-based sealer is formed.

[0062] As the water-based preconditioning liquid, an acidic liquid having a function of reacting with the water-based ink to thicken the water-based ink may be applied. The water-based preconditioning liquid of a strong acid may decompose polymer substances such as cellulose and lignin constituting the substrate. Therefore, the water-based preconditioning liquid applied to the printing surface of the substrate is preferably a weak acid rather than a strong acid. The water-based preconditioning liquid may be referred to as a treatment liquid, a pretreatment liquid, a reaction liquid, or the like.

[0063] The pH of the water-based preconditioning liquid is preferably 2 or more, and more preferably 3 or more. The water-based preconditioning liquid preferably has a neutral pH of about 7. The water-based preconditioning liquid may contain resin particles such as acrylic resin and urethane resin. The water-based preconditioning liquid may disperse pigment particles such as titanium oxide that function as white coloring material particles. This is effective when a preferable white base cannot be realized only by the undercoat layer obtained by drying the water-based sealer when a white base is formed on the printing surface of the substrate.

[0064] When performing inkjet printing on the printing surface of a substrate using an aqueous ink, it is preferable to use an aqueous sealer and an aqueous conditioning solution. Thereby, the adhesion of the aqueous ink to the substrate can be relatively improved.

[0065] The conditioning solution application device may apply roll coater coating. Roll coater coating supplies an aqueous conditioning solution to a rubber roll, transfers the aqueous conditioning solution to the printing surface of the substrate, and forms a coating film of the aqueous conditioning solution. Roll coater coating is suitable for forming a coating film such as a building material panel with a constant thickness.

[0066] The conditioning solution application device may apply inkjet coating. If it is an inkjet method, it is possible to apply the conditioning solution only to the places where it is necessary to apply the color ink, and the consumption amount of the conditioning solution can be suppressed as compared with the case where the conditioning solution is applied to the entire printing surface.

[0067] The application amount of the aqueous conditioning solution in the liquid state before the drying treatment may be 0.1 gram per square meter or more and 10 grams per square meter or less. The application amount of the aqueous conditioning solution may be 1.0 gram per square meter.

[0068] Also, the application amount of the aqueous conditioning solution in the liquid state before the drying treatment may be less than the application amount of the aqueous sealer in the liquid state before the drying treatment. For example, when the application amount of the aqueous sealer in the liquid state before the drying treatment is 100 grams per square meter, the application amount of the aqueous conditioning solution in the liquid state before the drying treatment may be 1.0 gram per square meter. After the conditioning solution application step S14, it proceeds to the conditioning solution drying step S16.

[0069] In the preconditioning liquid drying step S16, a preconditioning liquid drying device is used, and a drying process is performed on the aqueous preconditioning liquid applied to the printing surface of the substrate. The drying process may involve the application of heat and may involve the application of air blowing. The drying process may involve the appropriate combination of heat and air blowing as appropriate.

[0070] In the preconditioning liquid drying step S16, a specified processing temperature and a specified processing time are applied to dry the aqueous preconditioning liquid applied to the printing surface of the substrate. The preconditioning liquid drying step S16 may include a drying condition setting step. Before the execution of the preconditioning liquid drying step S16, the drying condition setting step may be executed. The drying conditions may include the processing temperature, the processing time, and the like. After the preconditioning liquid drying step S16, an aqueous ink application step S18 is executed.

[0071] In the aqueous ink application step S18, an inkjet printing device is used, and aqueous ink is applied onto the dried aqueous preconditioning liquid on the printing surface of the substrate, and an image based on image data is printed. The image may include characters, symbols, figures, patterns, and the like. The image data may be raster data or may be data in PDF format.

[0072] The aqueous ink is an ink in which solutes such as pigment particles and resin particles are dissolved or dispersed in a solvent having water as a main component. The aqueous ink used in the inkjet printing device preferably contains latex. The printed image using the aqueous ink containing latex has relatively improved surface abrasion resistance, and the production stability when the topcoat liquid is applied onto the dried ink can be relatively improved.

[0073] In addition, the printed image using the aqueous ink containing latex can be utilized as a printed matter without applying the topcoat liquid. Here, the term "printed matter" refers to a substrate having an image printed on the printing surface.

[0074] The resin particles contained in the aqueous ink may be of the same type as the resin particles contained in the aqueous sealer. When the same type of resin particles are contained in the aqueous ink and the aqueous sealer, the adhesion of the aqueous ink to the undercoat layer can be improved as compared with the case where different types of resin particles are contained.

[0075] The aqueous ink may be a functional ink in which particles of inorganic materials such as metals and particles of organic materials are dispersed or dissolved in a solvent mainly composed of water. The functional ink may exhibit specified performances such as conductivity in a dry state, while such performances may not be exhibited in a liquid state. After the aqueous ink application step S18, the process proceeds to the aqueous ink drying step S20.

[0076] The coating amount of the aqueous ink in the liquid state before the drying treatment may exceed the coating amount of the aqueous preconditioning liquid in the liquid state before the drying treatment. When the coating amount of the aqueous preconditioning liquid in the liquid state before the drying treatment is 1.0 gram per square meter, the coating amount of the aqueous ink in the liquid state before the drying treatment may be 10 grams per square meter.

[0077] In the aqueous ink drying step S20, an ink drying device is used, a specified treatment temperature and a specified treatment time are applied, and a drying treatment is performed on the printed image printed on the printing surface of the substrate.

[0078] The aqueous ink drying step S20 may include a drying condition setting step. Before the execution of the aqueous ink drying step S20, the drying condition setting step may be executed. The drying conditions may include the treatment temperature, the treatment time, and the like. After the aqueous ink drying step S20, the top coat liquid application step S22 is executed.

[0079] In the top coat liquid application step S22, a top coat liquid application device is used, the image of the aqueous ink is printed, and the top coat liquid is applied to the entire printing surface of the substrate on which the drying treatment has been performed. The top coat liquid may be a paint such as varnish and lacquer.

[0080] For the top coat liquid coating device, methods such as roll coater and curtain flow are applicable. Aqueous ink has a slower drying speed compared to solvent-based ink and ultraviolet curable ink, etc. The surface abrasion resistance in the printed image immediately after the drying process is relatively low, and there may be a case where the surface abrasion resistance is insufficient. Then, from the perspective of protecting the surface of the printed image, the non-contact curtain flow method may be preferable to the contact-type roll coater method in some cases.

[0081] For the top coat liquid coating device, an electrostatic spraying method, an electroplating method, a powder spraying method, and an immersion method may be applicable. After the top coat liquid coating step S22, a top coat liquid drying step S24 is executed.

[0082] In the top coat liquid drying step S24, a top coat liquid drying device is used, and a drying process is performed on the top coat liquid applied to the printed image of the aqueous ink. For the drying process, heating and blowing, etc. may be applicable. The drying process may be appropriately combined with heating and blowing.

[0083] The top coat liquid drying step S24 may include a drying condition setting step. Before executing the top coat liquid drying step S24, the drying condition setting step may be executed. The drying conditions may include the processing temperature and the processing time, etc.

[0084] For the top coat layer formed on the surface of the printed image, lamination processing of a resin sheet using a laminator may be applicable and formed. After the top coat liquid drying step S24, an inspection step S26 is executed.

[0085] In the inspection step S26, an inspection device is used to determine the presence or absence of defects in the printed image. Examples of defects in the printed image include dot omission, streaks, density unevenness, and color misregistration, etc. The inspection step S26 may include a photographing step of photographing the printed image using an image sensor, etc., a defect detection step of detecting defects in the printed image from the photographed data of the printed image, and an inspection result notification step of notifying the inspection result of the printed image.

[0086] For one base material, each process from the aqueous sealer application step S10 to the inspection step S26 is executed. When it is determined as a non-defective product without defects in the inspection step S26, one fiberboard structure is completed. When a specified number of fiberboard structures are manufactured, each process from the aqueous sealer application step S10 to the inspection step S26 is executed for each of the specified number of base materials. After the inspection step S26, an end determination step S28 is executed.

[0087] In the end determination step S28, a computer functioning as a control device determines whether a specified end condition is satisfied. Examples of the end condition include completion of the manufacture of a specified number of fiberboard structures, change of image data, and change of the base material.

[0088] In the end determination step S28, when the computer determines that the specified end condition is not satisfied, it is a No determination. In the case of a No determination, each process from the aqueous sealer application step S10 to the end determination step S28 is repeatedly executed until a Yes determination is made in the end determination step S28.

[0089] On the other hand, in the end determination step S28, when the computer determines that the specified end condition is satisfied, it is a Yes determination. In the case of a Yes determination, a specified end process is executed and the procedure of the fiberboard structure manufacturing method ends.

[0090] [Configuration example of fiberboard structure manufacturing system] FIG. 2 is a block diagram showing a configuration example of a fiberboard structure manufacturing system according to an embodiment. The arrow lines shown in the figure represent the movement of the base material. For the movement of the base material, a transport device for transporting the base material is applied.

[0091] The fiberboard structure manufacturing system 10 includes a base material supply device 12. The base material supply device 12 includes a base material storage unit that stores the base material to be printed, a base material extraction unit that extracts the base material one by one, and a base material carry-out unit that carries out the base material. The base material supply device 12 supplies the base materials one by one to the subsequent device at a specified timing.

[0092] The fiberboard structure manufacturing system 10 may include a sanding pretreatment device that performs sanding treatment on the base material carried out from the base material supply device 12. The sanding pretreatment device may carry out the base material on which the sanding treatment has been performed.

[0093] The fiberboard structure manufacturing system 10 includes a sealer coating device 14, a sealer drying device 16, and a sanding device 18. The sealer coating device 14 receives the base material carried out from the base material supply device 12, executes the water-based sealer coating process S10 illustrated in FIG. 1, and applies a water-based sealer to the printed surface of the base material.

[0094] The sealer drying device 16 receives the base material coated with the water-based sealer, executes the water-based sealer drying process S12, and performs a drying treatment on the printed surface of the base material coated with the water-based sealer. The sealer drying device 16 carries out the base material on which the undercoat layer obtained by drying the water-based sealer is formed on the printed surface.

[0095] The sanding device 18 receives the base material carried out from the sealer drying device 16, performs sanding treatment on the undercoat layer formed on the printed surface of the base material, and smoothes the undercoat layer. The sanding device 18 carries out the base material on which the undercoat layer has been smoothed.

[0096] The fiberboard structure manufacturing system 10 includes a preconditioning liquid coating device 20 and a preconditioning liquid drying device 22. The preconditioning liquid coating device 20 receives the base material with the smoothed undercoat layer carried out from the sanding device 18, executes the preconditioning liquid coating process S14, and applies a preconditioning liquid to the undercoat layer on the printed surface of the base material. The preconditioning liquid coating device 20 carries out the base material coated with the preconditioning liquid.

[0097] The preconditioning liquid drying device 22 receives a substrate coated with the preconditioning liquid, executes the preconditioning liquid drying step S16, and performs a drying process on the printing surface of the substrate coated with the preconditioning liquid.

[0098] The preconditioning liquid drying device 22 may adjust the temperature of the printing surface of the substrate to a temperature suitable for inkjet printing. The preconditioning liquid drying device 22 unloads the substrate on which a layer with the preconditioning liquid dried is formed.

[0099] The fiberboard structure manufacturing system 10 includes an inkjet printing device 24 and an ink drying device 26. The inkjet printing device 24 receives a substrate on which a layer with the preconditioning liquid dried is formed, executes the aqueous ink application step S18, and prints an image based on image data on the printing surface of the substrate. The inkjet printing device 24 unloads the substrate on which an image is printed on the printing surface.

[0100] The ink drying device 26 receives the substrate on which an image is printed on the printing surface, executes the aqueous ink drying step S20, and fixes the image on the printing surface of the substrate. The ink drying device 26 unloads the substrate on which the image is fixed on the printing surface.

[0101] The fiberboard structure manufacturing system 10 includes a top coat liquid application device 28 and a top coat liquid drying device 30. The top coat liquid application device 28 receives the substrate unloaded from the ink drying device 26, executes the top coat liquid application step S22, and applies the top coat liquid to the entire surface of the printing surface of the substrate. The top coat liquid application device 28 unloads the substrate coated with the top coat liquid.

[0102] The top coat liquid drying device 30 receives the base material carried out from the top coat liquid coating device 28, executes the top coat liquid drying step S24, and dries the top coat liquid applied to the entire printing surface of the base material. The top coat liquid drying device 30 carries out the fiberboard structure which is the base material with the top coat liquid dried on the printing surface where the image is printed.

[0103] The fiberboard structure manufacturing system 10 may include a laminating machine that laminates a resin sheet on the printing surface of the base material on which the image is printed, instead of the top coat liquid coating device 28 and the top coat liquid drying device 30.

[0104] The fiberboard structure manufacturing system 10 includes an inspection device 32. The inspection device 32 receives the fiberboard structure carried out from the top coat liquid drying device 30, executes the inspection step S26, and determines whether there is a defect in the image printed on the printing surface of the base material. That is, the inspection device 32 determines the quality of the fiberboard structure.

[0105] The inspection device 32 notifies the inspection result. The notification of the inspection result may display the character information representing the inspection result on the display, and may output the sound information representing the inspection result from the speaker. The inspection device 32 carries out the inspected fiberboard structure. The inspection device 32 may distinguish between good products and defective products and carry out the inspected fiberboard structure.

[0106] The inspection device 32 may receive the base material before the top coat layer is formed, carried out from the ink drying device 26, execute the inspection step S26, and determine whether there is a defect in the printed image in the base material before the top coat layer is formed.

[0107] The fiberboard structure manufacturing system 10 includes a fiberboard structure storage device 34. The fiberboard structure storage device 34 receives the fiberboard structure carried out from the inspection device 32 and stores the fiberboard structure. The fiberboard structure storage device 34 may store the good products and defective products of the fiberboard structure separately.

[0108] [Electrical Configuration of Fiberboard Structure Manufacturing System] Figure 3 is a functional block diagram showing the electrical configuration of the fiberboard structure manufacturing system illustrated in Figure 2. The fiberboard structure manufacturing system 10 illustrated in Figure 2 includes a control device 50.

[0109] The control device 50 is configured using a computer. The computer applied to the control device 50 may be a personal computer, may be a workstation, or may be a server computer.

[0110] Note that the processing function of the control device 50 may be realized as a computer system including a plurality of computers. The computer applied to the control device 50 may be a virtual machine.

[0111] The control device 50 includes a storage device 60. The storage device 60 stores various data, parameters, etc. used by the control device 50. The storage device 60 stores various programs executed by the control device 50. The storage device 60 may be configured as an external device of the control device 50. The storage device 60 may be configured as a combination of an external device of the control device 50 and an internal device of the control device 50.

[0112] The control device 50 includes a system control unit 52. The system control unit 52 comprehensively controls various processing units that make up the control device 50. The system control unit 52 functions as a memory driver that controls writing of data to the storage device 60 and reading of data from the storage device 60.

[0113] [[ID= (21)]]The control device 50 includes a data acquisition unit 54 and a parameter setting unit 56. The data acquisition unit 54 acquires various data such as print data transmitted from an external device. The data acquisition unit 54 stores the acquired various data in a specified storage device. The specified storage device may be the storage device 60. The parameter setting unit 56 sets various parameters.

[0114] The control device 50 includes a sensor information acquisition unit 58. The sensor information acquisition unit 58 acquires various sensor information transmitted from various sensors provided in the fiberboard structure manufacturing system 10. The various sensors may include a temperature sensor and a position detection sensor that detects the position of the base material.

[0115] The control device 50 includes a conveyance control unit 70. The conveyance control unit 70 controls the operation of a conveyance device 72 that conveys the base material based on a command signal transmitted from the system control unit 52. The conveyance control unit 70 controls the conveyance start timing of the base material, the stop timing of the base material, and the conveyance speed of the base material, etc.

[0116] The conveyance device 72 includes devices that convey the base material within various devices illustrated in FIG. 2. Further, the conveyance device 72 includes devices that convey the base material between various devices illustrated in FIG. 2.

[0117] The conveyance device 72 may include a base material supply device 12 and a fiberboard structure storage device 34 illustrated in FIG. 2. Further, the base material referred to here includes a fiberboard structure on which a prescribed image is printed on the base material.

[0118] The control device 50 includes a sealer application control unit 74. The sealer application control unit 74 sets sealer application conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the sealer application device 14.

[0119] The control device 50 includes a sealer drying control unit 76. The sealer drying control unit 76 sets sealer drying conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the sealer drying device 16.

[0120] The control device 50 includes a sanding control unit 77. The sanding control unit 77 sets sanding conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the sanding device 18.

[0121] The control device 50 includes a preconditioning liquid application control unit 78. The preconditioning liquid application control unit 78 sets preconditioning liquid application conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the preconditioning liquid application device 20.

[0122] The control device 50 includes a preconditioning liquid drying control unit 80. The preconditioning liquid drying control unit 80 sets preconditioning liquid drying conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the preconditioning liquid drying device 22.

[0123] The control device 50 includes a preconditioning liquid drying control unit 80. The preconditioning liquid drying control unit 80 sets preconditioning liquid drying conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the preconditioning liquid drying device 22. Note that the PC liquid in FIG. 3 represents the preconditioning liquid. The same applies to the PC liquid in FIG. 4.

[0124] The control device 50 includes a printing control unit 82. The printing control unit 82 sets printing conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the inkjet printing device 24. That is, the printing control unit 82 acquires printing data via the data acquisition unit 54, performs image processing on the printing data, and generates a drive voltage and a drive signal supplied to the inkjet head.

[0125] The control device 50 includes an ink drying control unit 84. The ink drying control unit 84 sets ink drying conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the ink drying device 26.

[0126] The control device 50 includes a top coat liquid application control unit 86. The top coat liquid application control unit 86 sets top coat liquid application conditions according to a command signal transmitted from the system control unit 52 and controls the operation of the top coat liquid application device 28.

[0127] The control device 50 includes a top coat liquid drying control unit 88. The top coat liquid drying control unit 88 sets top coat liquid drying conditions according to a command signal transmitted from the system control unit 52, and controls the operation of the top coat liquid drying device 30.

[0128] The control device 50 includes an inspection control unit 90. The inspection control unit 90 sets inspection conditions according to a command signal transmitted from the system control unit 52, and controls the operation of the inspection device 32. The inspection control unit 90 transmits the inspection result to the system control unit 52. The system control unit 52 generates a signal representing the inspection result and outputs a signal for notifying the inspection result.

[0129] FIG. 4 is a block diagram showing the hardware configuration of the electrical configuration of the fiberboard structure manufacturing system illustrated in FIG. 2. The control device 50 is applied to a computer including one or more processors and one or more memories storing a program including instructions executed by the one or more processors. The control device 50 may be configured using a plurality of computers.

[0130] The control device 50 illustrated in FIG. 4 includes a processor 102, a computer-readable medium 104, a communication interface 106, an input / output interface 108, and a bus 110.

[0131] The processor 102 includes a CPU. The processor 102 may include a GPU. Note that CPU is an abbreviation for Central Processing Unit. GPU is an abbreviation for Graphics Processing Unit.

[0132] The processor 102 is connected to the computer-readable medium 104, the communication interface 106, and the input / output interface 108 via the bus 110. The input device 112 and the display 114 are connected to the control device 50 via the input / output interface 108.

[0133] The control device 50 causes the processor 102 to execute a program stored in the computer-readable medium 104, thereby realizing various functions. Note that the term "program" is synonymous with the term "software".

[0134] The computer-readable medium 104 includes a memory 120 that is a main storage device and a storage 122 that is an auxiliary storage device. The computer-readable medium 104 can be applied to a semiconductor memory, a hard disk drive, a solid state drive device, etc. The computer-readable medium 104 can be applied to any combination of a plurality of devices.

[0135] Note that the hard disk drive can be referred to as an HDD, which is an abbreviation of Hard Disk Drive in English. The solid state drive device can be referred to as an SSD, which is an abbreviation of Solid State Drive in English.

[0136] The control device 50 performs data communication with an external device via the communication interface 106. The communication interface 106 can apply various standards such as USB. The communication form of the communication interface 106 can be either wired communication or wireless communication. Note that USB is an abbreviation of Universal Serial Bus and is a registered trademark.

[0137] The processor 102 has an input device 112 and a display 114 connected thereto via the input / output interface 108. The input device 112 can be an input device such as a keyboard and a mouse. The display 114 displays various information applied to the control device 50.

[0138] The display 114 is used as a part of the graphical user interface when receiving an input from the input device 112. Note that the display 114 is not limited to one, and a multi-display form including a plurality of displays is also possible.

[0139] The display 114 can be applied to a liquid crystal display, an organic EL display, a projector, or the like. The display 114 can be applied to any combination of a plurality of devices. Note that EL in the organic EL display is an abbreviation of Electro-Luminescence.

[0140] The memory 120 of the computer-readable medium 104 stores a conveyance program 130, a sealer application program 132, a sealer drying program 134, and a sanding program 136 that are executed by the processor 102.

[0141] The memory 120 stores a preconditioning liquid application program 138, a preconditioning liquid drying program 140, a printing program 142, and an ink drying program 144. The memory 120 stores a top coat liquid application program 146, a top coat liquid drying program 148, and an inspection program 150.

[0142] The conveyance program 130 is applied to the conveyance control unit 70 illustrated in FIG. 3 to realize the conveyance function of the substrate. The sealer application program 132 is applied to the sealer application control unit 74 to realize the application function of the aqueous sealer. The sealer drying program 134 is applied to the sealer drying control unit 76 to realize the drying function of the aqueous sealer. The sanding program 136 is applied to the sanding control unit 77 to realize the sanding function for the dried aqueous sealer.

[0143] The preconditioning liquid application program 138 is applied to the preconditioning liquid application control unit 78 to realize the application function of the preconditioning liquid. The preconditioning liquid drying program 140 is applied to the preconditioning liquid drying control unit 80 to realize the drying function of the preconditioning liquid.

[0144] The printing program 142 is applied to the print control unit 82 to realize the printing function. The printing program 142 may include an image processing program for generating halftone data from image data and a discharge control signal generation program for generating a discharge control signal for the inkjet head based on the halftone data.

[0145] The ink drying program 144 is applied to the ink drying control unit 84 to realize the ink drying function. The top coat liquid application program 146 is applied to the top coat liquid application control unit 86 to realize the application function of the top coat liquid. The top coat liquid drying program 148 is applied to the top coat liquid drying control unit 88 to realize the drying function of the top coat liquid. The inspection program 150 is applied to the inspection control unit 90 to realize the inspection function.

[0146] The various programs stored in the computer-readable medium 104 include one or more instructions. The computer-readable medium 104 stores various data and various parameters, etc.

[0147] Here, examples of the hardware structure of the processor 102 include a CPU, a GPU, a PLD (Programmable Logic Device), and an ASIC (Application Specific Integrated Circuit). The CPU is a general-purpose processor that executes programs and acts as various functional units. The GPU is a processor specialized for image processing.

[0148] The PLD is a processor whose circuit configuration can be changed after the device is manufactured. An example of the PLD is an FPGA (Field Programmable Gate Array). The ASIC is a processor equipped with a dedicated electric circuit designed specifically to execute a specific process.

[0149] One processing unit may be composed of one of these various processors, or may be composed of two or more processors of the same type or different types. Examples of combinations of various processors include combinations of one or more FPGAs and one or more CPUs, and combinations of one or more FPGAs and one or more GPUs. Other examples of combinations of various processors include combinations of one or more CPUs and one or more GPUs.

[0150] One processor may be used to configure a plurality of functional units. As an example of configuring a plurality of functional units using one processor, a combination of one or more CPUs such as an SoC (System On a Chip) and software, represented by a computer such as a client or a server, is applied to configure one processor, and this processor is made to act as a plurality of functional units.

[0151] Another example of configuring a plurality of functional units using one processor is a mode in which a processor that realizes the functions of an entire system including a plurality of functional units is used using one IC chip. Note that IC is an abbreviation for Integrated Circuit.

[0152] In this way, the various functional units are configured as a hardware structure using one or more of the various processors described above. Furthermore, the hardware structure of the various processors described above is more specifically an electrical circuit (circuitry) that combines circuit elements such as semiconductor elements.

[0153] [Modification Example of Control Device] The various processing units provided in the control device 50 illustrated in FIGS. 3 and 4 may be provided in the various devices that constitute the fiberboard structure manufacturing system 10 such as the sealer coating device 14 illustrated in FIG. 2.

[0154] For example, the data acquisition unit 54, the parameter setting unit 56, the sensor information acquisition unit 58, and the storage device 60 illustrated in FIG. 3 may be provided in each of the sealer coating devices 14 and the like. That is, each of the sealer coating devices 14 and the like may be provided with various control devices to which a computer is applied.

[0155] For example, the sealer coating control unit 74 may be provided in the sealer coating device 14. The control device of the sealer coating device 14 acquires a command signal transmitted from the control device 50, executes a sealer coating program based on the command signal, controls the operation of the sealer coating device 14, and may realize the coating function of the aqueous sealer. The same applies to the sealer drying device 16, the preconditioning liquid coating device 20, and the like.

[0156] [Specific Example of Sanding Process] FIGS. 5 to 7 are schematic diagrams showing the surface state of a substrate subjected to a sanding process. FIG. 5 represents the printing surface PF of the substrate S when lightly sanding is performed on the undercoat layer formed by applying one coat of the aqueous sealer and drying the aqueous sealer once, using sandpaper.

[0157] FIG. 6 represents the printing surface PF of the substrate S when sanding is performed on the undercoat layer formed by applying one coat of the aqueous sealer and drying the aqueous sealer once, using sandpaper with a particle size of #400. FIG. 7 represents the printing surface PF of the substrate S when the application of the aqueous sealer, the drying of the aqueous sealer, and the sanding using #400 sandpaper are repeated twice.

[0158] The printing surface PF of the substrate S illustrated in FIG. 6 is smoother and more slippery than the printing surface PF of the substrate S illustrated in FIG. 5. Further, the printing surface PF of the substrate S illustrated in FIG. 7 is smoother and more slippery than the printing surface PF of the substrate S illustrated in FIG. 6.

[0159] Sanding of the primer layer formed by applying and drying an aqueous sealer to the printing surface PF of the base material S may be defined in terms of the grit of the sandpaper, the pressing force of the sandpaper against the base material S, and the number of sanding passes, according to the type of the base material S, the type of the aqueous sealer, the type of the preconditioning liquid, etc. Note that the printing surface PF of the base material S described in the embodiment is an example of the first surface of the base material.

[0160] [Configuration Example of Inkjet Printing Apparatus] FIG. 8 is a configuration diagram of the inkjet printing apparatus illustrated in FIG. 2 and the like. FIG. 8 shows the inkjet printing apparatus 24 in a printing standby state. The inkjet printing apparatus 24 prints an image on the printing surface PF of the base material S using aqueous ink.

[0161] The inkjet printing apparatus 24 includes a printing conveyance device 200 to which a belt conveyance method is applied, which supports and conveys the base material S using a conveyance belt 202. The conveyance belt 202 is endless and wound around a driving roller and a driven roller. When the driving roller is rotated in a specified direction, the conveyance belt 202 travels in the specified direction, and the base material S supported by the conveyance belt 202 is conveyed in the specified conveyance direction. Note that illustration of the driving roller and the driven roller is omitted.

[0162] The conveyance method of the printing conveyance device 200 is not limited to the belt conveyance method, and conveyance methods such as a roller conveyance method, a nip conveyance method, and a drum conveyance method may be applied.

[0163] The inkjet printing apparatus 24 is supplied with a base material S having a printing surface on which an aqueous sealer is applied to the printing surface PF and a primer layer in which the aqueous sealer is dried is formed. The base material S supplied to the inkjet printing apparatus 24 is applied in a posture in which the surface opposite to the printing surface on which the primer layer is formed is supported by the conveyance belt 202.

[0164] The printing and conveying device 200 includes a loading section where the base material S unloaded from the devices in the previous stage such as the base material supply device 12 and the sanding device 18 shown in FIG. 2 is delivered. Further, the printing and conveying device 200 includes an unloading section for unloading the base material S to the devices in the subsequent stage.

[0165] The inkjet printing device 24 includes a pretreatment coater 204. The pretreatment coater 204 functions as a conditioning liquid application device 20 and a conditioning liquid drying device 22 shown in FIG. 2 and the like. The pretreatment coater 204 may be an external device of the inkjet printing device 24.

[0166] The inkjet printing device 24 includes a head section 206. The head section 206 includes an inkjet head 220W, an inkjet head 220K, an inkjet head 220C, an inkjet head 220M, and an inkjet head 220Y.

[0167] The head section 206 supports the inkjet heads 220W and the like, and includes a head moving section for moving the inkjet heads 220W and the like between a retracted position and a printing position. The head moving section may relatively move the base material and the inkjet heads 220W and the like to adjust the distance between the base material and the inkjet heads 220W and the like. The illustration of the head moving section is omitted.

[0168] The inkjet head 220W discharges white ink. The inkjet head 220K discharges black ink. The inkjet head 220C discharges cyan ink. The inkjet head 220M discharges magenta ink. The inkjet head 220Y discharges yellow ink. For example, as the inkjet heads 220W and the like, a Samba head manufactured by Fujifilm Corporation may be applied.

[0169] The inkjet printing apparatus 24 applies a single-pass method. That is, the inkjet printing apparatus 24 includes a line-type inkjet head 220W or the like. The line-type inkjet head has a structure in which a plurality of nozzle openings are formed over a length corresponding to the entire length in the width direction of the base material S in the width direction orthogonal to the conveyance direction of the base material S.

[0170] The line-type inkjet head may have a structure in which a plurality of head modules are joined together in the longitudinal direction. The plurality of head modules may be joined together in one example, or may be joined together in a zigzag pattern in two rows.

[0171] The inkjet printing apparatus 24 may apply multi-pass printing to which a serial method is applied. The inkjet head 220W or the like may be a serial-type inkjet head.

[0172] When the inkjet printing apparatus 24 is equipped with a line-type inkjet head and single-pass printing is performed, compared with the case where a serial-type inkjet head is equipped and serial printing is performed, relatively high productivity is realized. Note that the inkjet head 220W or the like described in the embodiment is an example of a discharge head of an inkjet method. The white ink described in the embodiment is an example of white ink.

[0173] FIG. 8 illustrates an aspect in which an inkjet head 220W that discharges white ink is provided. However, when the printing surface PF of the base material S has a white base, an aspect in which the inkjet head 220W is not provided may be used. Examples of the case where the printing surface PF of the base material S has a white base include the case where white colorant particles are dispersed in an aqueous sealer and the case where white colorant particles are dispersed in a preconditioning liquid.

[0174] The inkjet printing apparatus 24 includes an ink drying device 208. The ink drying device 208 illustrated in FIG. 8 functions as the ink drying device 26 illustrated in FIG. 2 etc., and dries the aqueous ink discharged from an inkjet head 220W etc. and applied to the printing surface PF of the substrate S.

[0175] The ink drying device 208 may include a heater that heats the aqueous ink applied to the printing surface PF of the substrate S. The heater may be an infrared heater. The infrared heater may be referred to as an IR heater. Note that IR is an abbreviation of InfraRed, the English notation for infrared rays.

[0176] The ink drying device 208 may include a blower fan that blows air onto the aqueous ink on the printing surface PF of the substrate S. The ink drying device 208 may combine the heater and the blower fan. The drying intensity of the ink drying device 208 is adjusted according to the type of the substrate S and the type of the aqueous ink. Examples of the adjustment of the drying intensity include adjustment of the processing temperature of the heater and adjustment of the air volume per unit time of the blower fan.

[0177] The inkjet printing apparatus 24 includes a top coat coater 210. The top coat coater 210 functions as the top coat liquid applying device 28 illustrated in FIG. 2 etc. A non-contact type such as a curtain flow method is applied to the top coat coater 210, and the top coat liquid is applied to the printing surface PF of the substrate S on which the printed image is printed.

[0178] The top coat coater 210 may apply the top coat liquid to the entire surface of the printing surface PF of the substrate S. The top coat coater 210 may selectively apply the top coat liquid to a part of the printing surface PF of the substrate S. Examples of a part of the printing surface PF of the substrate S include a region excluding a region where post-processing is performed on the substrate S and removed.

[0179] The inkjet printing apparatus 24 includes a topcoat liquid drying apparatus 212. The topcoat liquid drying apparatus 212 functions as the topcoat liquid drying apparatus 30 illustrated in FIG. 2 and the like, dries the topcoat liquid applied to the printing surface PF of the substrate S, and forms a topcoat layer.

[0180] Similar to the ink drying apparatus 208, the topcoat liquid drying apparatus 212 is provided with at least one of a heater and a blower fan. The drying intensity of the topcoat liquid drying apparatus 212 is adjusted according to the type of the substrate S, the type of the aqueous ink, and the type of the topcoat liquid.

[0181] The substrate S subjected to the drying treatment on the printing surface PF to which the topcoat liquid is applied is carried out of the inkjet printing apparatus 24 from the carrying-out portion as a fiberboard structure.

[0182] FIG. 9 is a configuration diagram showing the printing state of the inkjet printing apparatus illustrated in FIG. 8. FIG. 9 illustrates a printing state in which printing is performed on a part of the printing surface PF of the substrate S.

[0183] In the standby state illustrated in FIG. 8, the inkjet head 220W and the like are arranged at a standby position deviated from the position directly above the conveyor belt 202. In the printing state illustrated in FIG. 9, the inkjet head 220W and the like are moved to and stopped at the printing position directly above the conveyor belt 202 using the head conveyance apparatus.

[0184] The substrate S supported by the conveyor belt 202 is conveyed along the substrate conveyance direction in accordance with the running of the conveyor belt 202. The substrate conveyance direction is illustrated using an arrow line. Note that the substrate conveyance direction is synonymous with the conveyance direction of the substrate S.

[0185] When the substrate S reaches the processing region directly below the pretreatment coater 204, the pretreatment coater 204 applies a conditioning liquid to the entire printing surface PF of the substrate S and dries the applied conditioning liquid.

[0186] When the substrate S coated with the preconditioning liquid reaches the processing area directly below the inkjet head 220W, the inkjet head 220W ejects white ink onto the printing surface PF of the substrate S.

[0187] When the substrate S coated with the preconditioning liquid reaches the processing areas directly below the inkjet heads 220K, 220C, 220M, and 220Y respectively, each of the inkjet heads 220K etc. ejects color ink onto the printing surface PF of the substrate S. In this way, a color image using aqueous inks of white, black, cyan, magenta, and yellow is printed on the printing surface PF of the substrate S.

[0188] When the substrate S with a color printed image printed on the printing surface PF reaches the processing area of the ink drying device 208, a drying process is performed on the printing surface PF of the substrate S on which the printed image is printed.

[0189] When the substrate S on which the drying process has been performed on the printing surface PF of the substrate S with the printed image reaches the processing area of the top coat coater 210, a top coat liquid is applied to the printing surface PF of the substrate S on which the printed image is printed.

[0190] When the substrate S coated with the preconditioning liquid on the printing surface PF reaches the processing area of the top coat liquid drying device 212, a drying process is performed on the printing surface PF of the substrate S coated with the top coat liquid.

[0191] The substrate S that has passed through the processing area of the top coat liquid drying device 212 is carried out from the inkjet printing device 24 via the substrate carry-out unit. The substrate S carried out from the inkjet printing device 24 is conveyed to the inspection device 32.

[0192] FIGS. 8 and 9 illustrate an inkjet printing apparatus 24 including a pretreatment coater 204, an ink drying device 208, a topcoat coater 210, and a topcoat liquid drying device 212. However, the pretreatment coater 204 etc. may be devices external to the inkjet printing apparatus 24.

[0193] For example, the inkjet printing apparatus 24 may include a sealer application device 14 and a sealer drying device 16 in front of the pretreatment coater 204. Also, the inkjet printing apparatus 24 may include an inspection device 32 after the topcoat liquid drying device 212.

[0194] [Specific Examples of Fiberboard Structures] FIG. 10 is a cross-sectional view showing a structural example of the fiberboard structure. FIG. 10 shows a cross-section of the fiberboard structure SS orthogonal to the printing surface PF of the base material S. The base material S is the wood fiberboard itself, and a primer layer Se, an ink layer Ink, and a topcoat layer Tc are laminated in this order on the printing surface PF.

[0195] A moisture-proof layer Mo is formed on the non-printing surface NPF of the base material S on the side opposite to the printing surface PF. The wood fiberboard constituting the base material S may deteriorate due to moisture absorption. Therefore, it is preferable to form the moisture-proof layer Mo on the non-printing surface NPF of the base material S in advance.

[0196] The formation of the moisture-proof layer Mo may be applied by attaching a moisture-proof sheet such as a moisture-proof film and moisture-proof paper to the non-printing surface NPF. The moisture-proof layer Mo is preferably formed prior to the application of an aqueous sealer. The moisture-proof layer Mo is preferably formed before the execution of the printing process. Before the execution of the printing process, it may be before the application of the preconditioning liquid. Note that the non-printing surface NPF of the base material S described in the embodiment is an example of the second surface on the side opposite to the first surface of the base material.

[0197] [Operational Effects of the Embodiment] The fiberboard structure manufacturing method, fiberboard structure manufacturing system, and fiberboard structure according to the embodiment can obtain the following operational effects.

[0198] 〔1〕 An aqueous sealer is applied to the printing surface PF of the base material S to which the wood fiber board is applied, and the aqueous sealer is dried to form an undercoat layer. A conditioning liquid that reacts with the aqueous ink to thicken the aqueous ink is applied to the undercoat layer, and inkjet printing using the aqueous ink is performed on the printing surface PF of the base material S to which the conditioning liquid is applied.

[0199] The undercoat layer suppresses the penetration of the ink into the base material S, and realizes a preferable color development of the ink. Further, the conditioning liquid immediately fixes the ink droplets landing on the undercoat layer to the undercoat layer, and suppresses the deterioration of the quality of the printed image due to the displacement of the ink dots.

[0200] 〔2〕 The aqueous sealer and the aqueous ink contain the same kind of resin particles. Thereby, the adhesion between the aqueous ink and the undercoat layer dried from the aqueous sealer can be relatively improved.

[0201] 〔3〕 The volume per unit area of the aqueous sealer in the liquid state before drying exceeds the volume per unit area of the aqueous ink in the liquid state before drying. Thereby, the thickness of the aqueous sealer becomes thicker than the thickness of the aqueous ink, and the penetration of the aqueous ink into the base material S is effectively suppressed.

[0202] 〔4〕 The aqueous sealer contains white colorant particles. Thereby, printing of an image on a white base is realized. Further, printing of a white object is possible on a base of a color other than white.

[0203] 〔5〕 The conditioning liquid contains white colorant particles. Thereby, a preferable white base can be formed even when the white base is not sufficient only with the undercoat layer of the aqueous sealer.

[0204] 〔6〕 The inkjet printing apparatus 24 includes an inkjet head 220W that discharges white ink containing white coloring material particles. Thereby, printing of a color image with white ink as a base is realized. Also, a white object can be printed on a base of a color other than white.

[0205] [7] A topcoat liquid is applied to a printed surface on which an image is printed using aqueous ink, and the applied topcoat liquid is dried. Thereby, the rub resistance of the image printed using aqueous ink can be relatively improved.

[0206] [8] A non-contact process is applied for the application of the topcoat liquid. Thereby, the rub resistance of the printed image printed using aqueous ink when the topcoat liquid is applied can be relatively improved.

[0207] [9] A moisture-proof layer Mo is formed on the non-printed surface NPF of the base material S prior to the printing process. Thereby, deterioration of the base material S due to absorption of moisture by the base material S is suppressed.

[0208]

[10] The printed surface PF of the base material S is subjected to a sanding treatment. Thereby, fuzz on the printed surface PF of the base material S is removed, and an aqueous sealer can be uniformly applied.

[0209]

[11] The undercoat layer Se formed on the printed surface PF of the base material S is subjected to a sanding treatment. Thereby, the surface of the undercoat layer Se is smoothed, and a preconditioning liquid can be uniformly applied.

[0210] The embodiments of the present invention described above can be appropriately modified, added to, or deleted without departing from the gist of the present invention. The present invention is not limited to the embodiments described above, and many modifications are possible by those having ordinary knowledge in the art within the technical idea of the present invention. Also, embodiments, modification examples, and application examples may be implemented in appropriate combinations.

Description of Symbols

[0211] 10 Fiberboard Structure Manufacturing System 12 Base Material Feeding Device 14 Sealer Coating Device 16 Sealer Drying Device 18 Sanding Device 20 Preconditioning Liquid Coating Device 22 Preconditioning Liquid Drying Device 24 Inkjet Printing Device 26 Ink Drying Device 28 Top Coat Liquid Coating Device 30 Top Coat Liquid Drying Device 32 Inspection Device 34 Fiberboard Structure Storage Device 50 Control Device 52 System Control Unit 54 Data Acquisition Unit 56 Parameter Setting Unit 58 Sensor Information Acquisition Unit 60 Storage Device 70 Conveyance Control Unit 72 Conveyance Device 74 Sealer Coating Control Unit 76 Sealer Drying Control Unit 77 Sanding Control Unit 78 Preconditioning Liquid Coating Control Unit 80 Preconditioning Liquid Drying Control Unit 82 Printing Control Unit 84 Ink Drying Control Unit 86 Top Coat Liquid Coating Control Unit 88 Top Coat Liquid Drying Control Unit 90 Inspection Control Unit 102 Processor 104 Computer Readable Medium 106 Communication Interface 108 Input / Output Interface 110 Bus 112 Input Device 114 Display 120 Memory 122 Storage 130 Conveyance Program 132 Sealer Coating Program 134 Sealer Drying Program 136 Sanding Program 138 Preconditioning Liquid Coating Program 140 Preconditioning Liquid Drying Program 142 Printing Program 144 Ink Drying Program 146 Top Coat Liquid Coating Program 148 Top Coat Liquid Drying Program 150 Inspection Program 200 Printing Conveyor 202 Conveyor Belt 204 Pretreatment Coater 206 Head Unit 208 Ink Drying Device 210 Top Coat Coater 212 Top Coat Liquid Drying Device 220C Inkjet Head 220K Inkjet Head 220M Inkjet Head 220W Inkjet Head 220Y Inkjet Head Ink Ink Layer Mo Moisture-proof Layer NPF Non-printing Surface PF Printing Surface S Substrate Se Undercoat Layer Tc Top Coat Layer Steps of the method for manufacturing a fiberboard structure from S10 to S28

Claims

1. A primer layer is formed on the first surface of a base material on which a fiberboard is used by drying an aqueous sealer applied to the first surface, An aqueous preconditioning liquid having a function of thickening an aqueous ink is applied to the first surface on which the primer layer is formed, An inkjet method discharge head discharges an aqueous ink, and the aqueous ink is applied to the first surface to which the aqueous preconditioning liquid is applied. A method for manufacturing a fiberboard structure.

2. The method for manufacturing a fiberboard structure according to claim 1, wherein the aqueous sealer and the aqueous ink contain the same type of resin.

3. The method for manufacturing a fiberboard structure according to claim 1, wherein the aqueous sealer is applied thicker than the aqueous ink.

4. The method for manufacturing a fiberboard structure according to claim 1, wherein the aqueous sealer contains white coloring material particles.

5. The aqueous ink contains a white ink containing white coloring material particles, The method for manufacturing a fiberboard structure according to claim 1, wherein the white ink is applied to the first surface to which the aqueous preconditioning liquid is applied.

6. A coating liquid is applied to the first surface to which the aqueous ink is applied. The method for manufacturing a fiberboard structure according to claim 1.

7. The method for manufacturing a fiberboard structure according to claim 6, wherein a non-contact process is applied to the application of the coating liquid.

8. A moisture-proof layer is formed on the second surface opposite to the first surface of the base material. The method for manufacturing a fiberboard structure according to claim 1.

9. A sanding treatment is performed on the first surface of the base material. The method for manufacturing a fiberboard structure according to claim 1.

10. The aqueous sealer applied to the first surface of the base material is dried, and a primer layer is formed on the first surface of the base material. The method for manufacturing a fiberboard structure according to claim 1.

11. A sanding treatment is performed on the primer layer formed on the first surface of the base material. The method for manufacturing a fiberboard structure according to claim 1.

12. A sealer coating device for applying an aqueous sealer to the first surface of a base material to which a fiberboard is applied, A preconditioning liquid coating device for applying an aqueous preconditioning liquid having a function of thickening an aqueous ink to the first surface on which a primer layer formed by drying the aqueous sealer is formed, An inkjet ejection head that ejects an aqueous ink and applies the aqueous ink to the first surface coated with the aqueous preconditioning liquid, A fiberboard structure manufacturing system comprising the same.

13. A substrate to which a fiberboard is applied, An undercoat layer obtained by drying an aqueous sealer applied to the first surface of the substrate, An ink layer that thickens by reacting with the aqueous preconditioning liquid having a function of thickening the aqueous ink, where the aqueous ink applied to the aqueous preconditioning liquid applied to the undercoat layer thickens, A fiberboard structure comprising the same.

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