Partitions, panels for partitions, and buildings

Abstract

To provide a partition board with high design quality, a panel for the partition board, and a building. A partition plate (10) includes a frame (20) and a panel (50) attached to the frame. The panel includes a metal substrate (55) containing an Al-Mn alloy and a design layer (56) laminated on the metal substrate.

Description

[Technical Field]

[0001] The present disclosure relates to a partition board, a panel for a partition board, and a building. [Background technology]

[0002] Partitions are often installed on the verandas of apartment buildings to separate adjacent dwelling units. These partitions clearly define the boundaries between adjacent dwelling units and serve to ensure privacy by blocking the line of sight between residents. Some partitions can also be broken down to allow evacuees to pass through in the event of an emergency such as a fire (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-174308 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional partitions have limited variations in appearance, and as a result, in apartment buildings that use conventional partitions, it is often difficult to unify the design of the partitions with the design of the exterior walls.

[0005] The present disclosure provides a partition board, a panel for the partition board, and a building with a high design quality. [Means for solving the problem]

[0006] The embodiments of the present disclosure relate to the following [1] to

[15] .

[0007] [1] A partition plate comprising a frame and a panel attached to the frame, the panel including a metal substrate containing an Al-Mn alloy and a design layer laminated on the metal substrate.

[0008] [2] A partition plate comprising a frame and a panel attached to the frame, the panel including a metal substrate and a decorative layer laminated on the metal substrate, stud bolts fixed to the panel, and the panel attached to the frame by the stud bolts.

[0009] [3] The partition plate according to [1] or [2], wherein the thickness of the metal substrate is 1.0 mm or more.

[0010] [4] The partition plate according to [1], wherein a stud bolt is fixed to the panel.

[0011] [5] The partition plate according to [2] or [4], wherein the stud bolt contains aluminum or iron.

[0012] [6] A partition plate according to any one of [1] to [5], further comprising a kick-off plate held by the frame.

[0013] [7] A partition plate according to any one of [1] to [6], wherein the panel is arranged outside the frame.

[0014] [8] A partition plate described in any one of [1] to [7], wherein the frame has a lower frame, an upper frame, an outer frame, and an inner frame, the outer frame has an outer groove portion, and the outer groove portion contains a decorative material.

[0015] [9] A partition plate described in any one of [1] to [8], wherein the panel has an area on the first surface located on the decorative layer side relative to the metal substrate, where the flop index is 4.5 or more.

[0016]

[10] A partition plate according to any one of [1] to [9], wherein the decorative layer contains an organic colorant.

[0017]

[11] A partition plate according to any one of [1] to

[10] , wherein the design layer is a baked layer.

[0018]

[12] A separator according to any one of [1] to

[11] , wherein the panel is subjected to an accelerated weathering test using a sunshine weather meter, and when the ultraviolet irradiation time reaches a total of 10,000 hours, the color difference (ΔE) before and after the accelerated weathering test is 7 or less.

[0019]

[13] A panel for a partition plate, comprising: a metal substrate containing an Al-Mn alloy; and a design layer laminated on the metal substrate.

[0020]

[14] The panel according to

[13] , further comprising a stud bolt fixed to the metal substrate.

[0021]

[15] A building equipped with a partition plate according to any one of [1] to

[12] . [Effects of the Invention]

[0022] According to the present disclosure, a partition plate with excellent design can be provided. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a front view showing a partition plate according to a first embodiment. [Figure 2] FIG. 2 is a vertical cross-sectional view (cross-sectional view taken along line II-II in FIG. 1) showing the partition plate according to the first embodiment. [Figure 3] FIG. 3 is a cross-sectional view taken along line III-III in FIG. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Figure 5] FIG. 5 is a front view showing a partition plate according to a modified example of the first embodiment. [Figure 6] FIG. 6 is a front view showing a partition plate according to the second embodiment. [Figure 7] FIG. 7 is a vertical cross-sectional view (cross-sectional view taken along line VII-VII in FIG. 6) showing a partition plate according to the second embodiment. [Figure 8] FIG. 8 is a horizontal cross-sectional view (cross-sectional view taken along line VIII-VIII in FIG. 6) showing a partition plate according to the second embodiment. [Figure 9] FIG. 9 is a schematic cross-sectional view illustrating an example panel. [Figure 10] FIG. 10 is a schematic cross-sectional view illustrating a modified example of the panel. [Figure 11] 11(a) to 11(e) are schematic cross-sectional views illustrating a method for manufacturing a panel. [Figure 12] FIG. 12 is a graph showing the results of Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. [Figure 13] FIG. 13 is a graph showing the results of Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. [Figure 14] FIG. 14 is a graph showing the results of Examples 3-1 to 3-4. [Figure 15] FIG. 15 is a graph showing the results of Examples 4-1 to 4-4. DETAILED DESCRIPTION OF THE INVENTION

[0024] (First embodiment) A first embodiment will be described below with reference to FIGS. 1 to 4. However, the present disclosure can be implemented in many different forms and should not be limited to the description of the embodiments exemplified below. Furthermore, to clarify the explanation, the drawings may show the width, thickness, and shape of each part more schematically than the actual form, but this is merely an example and should not be interpreted as limiting. In the following drawings, the same parts are denoted by the same reference numerals, and some detailed explanations may be omitted.

[0025] In this specification, when describing a mode in which another component is disposed on a certain component, the term "above" or "below" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified. Also, in this specification, when describing a mode in which another component is disposed on the surface of a certain component, the term "on the surface" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified.

[0026] (Configuration of partition plate) The partition plate according to this embodiment will be outlined with reference to Figures 1 to 4. Figures 1 to 4 are views showing the partition plate according to this embodiment.

[0027] The partition 10 shown in Figures 1 to 4 is a partition wall that separates a balcony of a building 90, such as an apartment building. The partition 10 includes a frame 20 and a panel 50. The panel 50 is attached to the frame 20. The panel 50 includes a metal base material 55 and a design layer 56 laminated on the metal base material 55.

[0028] According to this embodiment, the panel 50 includes a metal base material 55 and a design layer 56 laminated on the metal base material 55. This enhances the design of the partition plate 10. Furthermore, the design of the partition plate 10 can be matched to the design of the building 90, thereby achieving a unified design between the partition plate 10 and the building 90. Furthermore, the metal base material 55 may include an Al-Mn alloy. A metal base material 55 containing an Al-Mn alloy has higher strength than a typical aluminum plate. Therefore, the baking temperature for baking the design layer 56 onto the metal base material 55 can be set to a high temperature, thereby improving the weather resistance of the panel 50.

[0029] Frame As shown in Figure 1, the frame 20 is fixed to the balcony floor surface 91, the balcony top surface 92, and the building exterior wall surface 93. The frame 20 has a lower frame 21, an upper frame 22, an outer frame 23, and an inner frame 24. The frame 20 has a rectangular shape when viewed from the normal direction of the main surface member 51 of the panel 50. A first inner crosspiece 25 and a second inner crosspiece 26 are located between the lower frame 21 and the upper frame 22.

[0030] The lower frame 21 is located at the bottom of the frame 20. The lower frame 21 extends horizontally. The lower frame 21 connects the outer frame 23 and the inner frame 24 to each other. The lower frame 21 is fixed to the balcony floor 91 via lower fixing brackets 31. A panel 50 is attached to the lower frame 21 by a hook bracket 35 attached to the panel 50 (see Figure 2).

[0031] The upper frame 22 is located at the top of the frame 20. The upper frame 22 extends horizontally. The upper frame 22 connects the outer frame 23 and the inner frame 24 to each other. The upper frame 22 is fixed to the top surface 92 of the balcony via upper fixing brackets 32.

[0032] The outer frame 23 is located on the outer edge of the frame 20 (opposite the building outer wall surface 93). The outer frame 23 extends vertically between the floor surface 91 and the top surface 92 of the balcony.

[0033] The inner frame 24 is located on the inner edge of the frame 20 (on the building exterior wall surface 93 side). The inner frame 24 extends vertically between the balcony floor surface 91 and the top surface 92. The inner frame 24 is fixed to the building exterior wall surface 93 via inner fixing brackets 33. The inner fixing brackets 33 extend vertically and are attached to the building exterior wall surface 93 with bolts 34.

[0034] The first inner crosspiece 25 is located between the lower frame 21 and the second inner crosspiece 26. The first inner crosspiece 25 extends horizontally. The first inner crosspiece 25 connects the outer frame 23 and the inner frame 24 to each other. The panel 50 is attached to the first inner crosspiece 25 by a hook 35 attached to the panel 50.

[0035] A pair of plate mounting frames 27, 28 are located between the first middle crosspiece 25 and the lower frame 21. One plate mounting frame 27 is located on the outer frame 23 side, and the other plate mounting frame 28 is located on the inner frame 24 side. Each of the pair of plate mounting frames 27, 28 extends vertically. Each of the pair of plate mounting frames 27, 28 connects the first middle crosspiece 25 and the lower frame 21 to each other. A kick-off plate 30 is fitted into the pair of plate mounting frames 27, 28.

[0036] The kick-off board 30 can be destroyed by evacuees kicking it down in the event of an emergency such as a fire. The kick-off board 30 is a rectangular plate-like member. The kick-off board 30 is held by the frame 20. The kick-off board 30 is surrounded by the first middle crosspiece 25, the pair of board mounting frames 27, 28, and the bottom frame 21. The periphery of the kick-off board 30 is accommodated in grooves provided in the first middle crosspiece 25, the pair of board mounting frames 27, 28, and the bottom frame 21. Note that FIG. 3 shows the groove 27b of the board mounting frame 27, and FIG. 4 shows the groove 21b of the bottom frame 21. The material of the kick-off board 30 may be, for example, flexible board (fiber-reinforced cement board), plywood, calcium silicate board (calcium silicate board), gypsum, etc.

[0037] It should be noted that, for example, if the partition 10 is not installed in the evacuation route, the kick-off plate 30 does not necessarily have to be provided.

[0038] The second middle crosspiece 26 is located between the first middle crosspiece 25 and the upper frame 22. The second middle crosspiece 26 extends horizontally. The second middle crosspiece 26 connects the outer frame 23 and the inner frame 24 to each other. The panel 50 is attached to the second middle crosspiece 26 by a hook 35 attached to the panel 50.

[0039] [panel] The panel 50 is disposed on the outside of the frame 20. The panel 50 covers the frame 20 so that the frame 20 is substantially invisible from the outside. In this case, two panels 50 are attached to the frame 20. The two panels 50 face opposite each other across the frame 20. That is, one panel 50 faces the balcony side of one dwelling unit, and the other panel 50 faces the balcony side of the adjacent dwelling unit. The two panels 50 have substantially symmetrical shapes. The panel 50 may also be called a decorative member.

[0040] The panel 50 includes a metal substrate 55 and a design layer 56 laminated on the metal substrate 55. The design layer 56 may be laminated directly on the metal substrate 55, or may be laminated via another layer (such as a primer layer 57 and a base layer 58, which will be described later). The design layer 56 is weather resistant and also has design properties. Therefore, by matching the design of the design layer 56 with the building exterior wall surface 93 of the building 90, a unified appearance of the building 90 can be provided.

[0041] The panel 50 has a main surface member 51, a top surface member 52, and an outer surface member 53. The top surface member 52 and the outer surface member 53 are each bent at a right angle to the main surface member 51.

[0042] The main surface member 51 constitutes the widest surface of the panel 50. The main surface member 51 faces the balcony side of the dwelling unit. The main surface member 51 has a rectangular outer periphery. Each side of the main surface member 51 extends along the lower frame 21, inner frame 24, upper frame 22, and outer frame 23 of the frame 20, respectively.

[0043] A rectangular opening 51a is formed in the main surface member 51. The kick plate 30 is exposed to the outside from the opening 51a. The main surface member 51 is bent toward the inside of the opening 51a to form an inner bent portion 51b (see FIG. 4). The tip of the inner bent portion 51b faces the kick plate 30.

[0044] The top surface member 52 is located at the vertical upper part of the panel 50. The top surface member 52 is located parallel to the horizontal direction. The top surface member 52 is arranged to cover the upper frame 22 of the frame 20. As shown in FIG. 2 , the top surface member 52 of one panel 50 and the top surface member 52 of the other panel 50 are arranged to face each other on the upper frame 22. The top surface member 52 and the upper frame 22 are fixed integrally to the upper fixing bracket 32.

[0045] The outer surface member 53 faces the outside of the panel 50 (the side opposite to the building exterior wall surface 93). The outer surface member 53 extends in the vertical direction. The outer surface member 53 is arranged to cover the outer frame 23 of the frame 20. As shown in FIG. 3 , the outer surface member 53 of one panel 50 and the outer surface member 53 of the other panel 50 are arranged to face each other on the outer frame 23.

[0046] The panel 50 is attached to the frame 20 by stud bolts 36. Specifically, the stud bolts 36 are fixed to the panel 50, protruding inward (toward the frame 20). The stud bolts 36 are fixed to a metal base material 55 of the panel 50 by welding or the like. The panel 50 is attached to the frame 20 by inserting the stud bolts 36 of the panel 50 into bolt openings in the frame 20 and screwing nuts 37 onto the stud bolts 36. The stud bolts 36 may be made of aluminum or iron.

[0047] As shown in Fig. 2, the panel 50 is attached to the upper frame 22 of the frame 20 by stud bolts 36 provided on the main surface member 51. Furthermore, by fixing hooks 35 to the stud bolts 36 provided on the main surface member 51 and fitting the hooks 35 into the bottom frame 21, first inner cross member 25, and second inner cross member 26 of the frame 20, the panel 50 is fixed to the bottom frame 21, first inner cross member 25, and second inner cross member 26 of the frame 20. Furthermore, as shown in Fig. 4, the panel 50 is attached to the bottom frame 21 of the frame 20 by stud bolts 36 provided on the main surface member 51.

[0048] As shown in Fig. 2, a top surface member 52 of the panel 50 and the upper frame 22 of the frame 20 are fixed to each other by fastening members 38a such as screws. As shown in Fig. 3, an outer surface member 53 of the panel 50 and the outer frame 23 of the frame 20 are fixed to each other by fastening members 38b such as screws. As shown in Fig. 4, an inner bent portion 51b of the panel 50 and the lower frame 21 of the frame 20 are fixed to each other by fastening members 38c such as screws.

[0049] The detailed configuration of the panel 50 will be described later.

[0050] Fig. 5 is a diagram showing a modified example of the partition plate 10 according to the present embodiment. As shown in Fig. 5, a fence 94 is provided on the floor surface 91 of the balcony. The outer frame 23 of the frame 20 and the outer surface member 53 of the panel 50 may be fixed to the fence 94.

[0051] According to this embodiment, the panel 50 of the partition plate 10 includes a design layer 56 laminated on a metal base material 55. By including the design layer 56 in the partition plate 10, the design of the partition plate 10 can be enhanced. Furthermore, the design of the design layer 56 can be changed as appropriate. For example, by matching the design of the design layer 56 with the design of the building exterior wall surface 93 of the building 90, a unified appearance of the building 90 can be provided.

[0052] Furthermore, according to this embodiment, the panel 50 of the partition plate 10 may include a metal substrate 55 containing an Al-Mn alloy. The metal substrate 55 containing an Al-Mn alloy has greater strength than pure aluminum. Therefore, the decorative layer 56 can be baked onto the metal substrate 55 at a high temperature. By baking the decorative layer 56 at a high temperature, the weather resistance of the decorative layer 56 can be improved.

[0053] Furthermore, according to this embodiment, the stud bolts 36 are fixed to the metal base material 55 of the panel 50, and the panel 50 is attached to the frame 20 by the stud bolts 36. This allows the panel 50 to be firmly attached to the frame 20. Furthermore, as will be described later, when the thickness of the metal base material 55 is 1.0 mm or more, the metal base material 55 is sufficiently thick so that the stud bolts 36 can be welded to the surface of the metal base material 55 opposite the design layer 56. Therefore, traces of the stud bolts 36 fixed to the metal base material 55 do not substantially appear on the design layer 56 side. This prevents the design of the design layer 56 from being impaired by the traces of the stud bolts 36.

[0054] Furthermore, according to the present embodiment, the panel 50 is attached to the outside of the frame 20. In this case, the frame 20 covered by the panel 50 cannot be seen from the outside, and therefore, it is possible to prevent the frame 20 from deteriorating the design of the panel 50.

[0055] (Second embodiment) The second embodiment will be described with reference to Figures 6 to 8. In Figures 6 to 8, the same parts as those in the first embodiment shown in Figures 1 to 5 are designated by the same reference numerals, and detailed description thereof will be omitted.

[0056] (Configuration of partition plate) The partition plate according to this embodiment will be outlined below with reference to Figures 6 to 8. Figures 6 to 8 are diagrams showing the partition plate according to this embodiment.

[0057] 6 to 8, the partition plate 10 includes a frame 20 and a panel 50. The panel 50 is attached to the frame 20. The panel 50 includes a metal base material 55 and a design layer 56 laminated on the metal base material 55.

[0058] Frame 6, the frame 20 has a lower frame 21, an upper frame 22, an outer frame 23, and an inner frame 24. A first inner crosspiece 25 and a second inner crosspiece 26 are positioned between the lower frame 21 and the upper frame 22.

[0059] 7, a first holding member 21a that holds the kick-off plate 30 is attached to the upper part of the lower frame 21. The first holding member 21a has a first groove portion 21b that houses the kick-off plate 30. A first pressing member 21c that presses down the kick-off plate 30 is disposed in the first groove portion 21b.

[0060] A second holding member 25a that holds the kick-off plate 30 is attached to the lower part of the first middle crosspiece 25. The second holding member 25a has a second groove portion 25b that houses the kick-off plate 30. A second pressing member 25c that presses down the kick-off plate 30 is disposed in the second groove portion 25b.

[0061] First holding member 21a, second holding member 25a, first pressing member 21c, and / or second pressing member 25c may be made of the same plate material as panel 50. That is, first holding member 21a, second holding member 25a, first pressing member 21c, and / or second pressing member 25c may include a metal base material and a design layer laminated on the metal base material. This enhances the design around kick plate 30 and provides a design that is integrated with panel 50.

[0062] As shown in FIG. 8, a molding material 29 is attached to the outer frame 23. The outer frame 23 also has an outer groove portion 23a. The outer groove portion 23a extends vertically between the floor surface 91 and the top surface 92 of the balcony. A decorative material 23b is housed in the outer groove portion 23a. The decorative material 23b may include a metal base material and a decorative layer laminated on the metal base material. The decorative material 23b enhances the design of the outer frame 23 side of the partition plate 10 and provides a design that is integrated with the panel 50.

[0063] 6, the outer frame 23 and decorative material 23b extend vertically downward below the balcony floor surface 91. This enhances the design below the balcony floor surface 91 and provides a design that is integrated with the panel 50.

[0064] 8, the inner frame 24 has an inner groove 24a that extends vertically between the balcony floor surface 91 and the ceiling surface 92. The inner frame 24 is attached to the building exterior wall surface 93 at the inner groove 24a with inner fixing brackets 33 and bolts 34.

[0065] 8, a third holding member 27a and a fourth holding member 28a that hold the kick-off plate 30 are attached to the pair of plate mounting frames 27, 28. The third holding member 27a and the fourth holding member 28a have a third groove portion 27b and a fourth groove portion 28b that accommodate the kick-off plate 30, respectively.

[0066] [panel] The panel 50 is disposed on the outside of the frame 20. In this embodiment, the panel 50 has a main surface member 51, but does not have a top surface member or an outer surface member. In other words, the panel 50 is composed of a plate-like member that does not have any bent portions. However, this is not limiting, and the panel 50 may also have a top surface member 52 or an outer surface member 53.

[0067] 6, the main surface member 51 has a downward extension 51c that extends vertically downward below the balcony floor surface 91. The downward extension 51c enhances the design below the balcony floor surface 91, providing a design that is integrated with the panel 50.

[0068] As shown in FIG. 7 , the panel 50 is attached to the frame 20 with stud bolts 36. Specifically, the stud bolts 36 are fixed to the panel 50, protruding inward (toward the frame 20). The stud bolts 36 are fixed to a metal base material 55 of the panel 50 by welding or the like. Specifically, the stud bolts 36 provided on the panel 50 are inserted into openings in mounting brackets 39, and nuts 37 are screwed onto the stud bolts 36. The mounting brackets 39 are then attached to the lower frame 21, thereby attaching the panel 50 to the frame 20. The panel 50 is also attached to the first inner crosspiece 25 of the frame 20 by fixing hooks 35 to the stud bolts 36 provided on the panel 50 and fitting the hooks 35 into the first inner crosspiece 25 of the frame 20.

[0069] The detailed configuration of the panel 50 will be described later.

[0070] According to this embodiment, the outer frame 23 of the frame 20 has an outer groove portion 23a, and the outer groove portion 23a accommodates the decorative material 23b, thereby improving the design of the outer frame 23 of the frame 20 when viewed from the outside.

[0071] (Panel and panel manufacturing method) The partition panels and the manufacturing methods of the panels in the above-described embodiments will be described in detail below.

[0072] A. Panel 9 and 10 are schematic cross-sectional views illustrating a panel 50 according to the present embodiment. As shown in FIG. 9, the panel 50 includes a metal base material 55 and a design layer 56, and is arranged in a thickness direction D T The panel 50 has the above-mentioned layers in this order. The design layer 56 contains an organic colorant. The panel 50 may have a region in the first surface 50a, which is located on the design layer 56 side with respect to the metal substrate 55, where the flop index is 4.5 or more. As shown in FIG. 10 , the panel 50 has the metal substrate 55, the primer layer 57, the undercoat layer 58, the design layer 56, and the surface protective layer 59 arranged in the thickness direction D. TIn this order,

[0073] In the present embodiment, the design layer 56 may contain an organic colorant, and the flop index on the first surface 50a may be 4.5 or higher. In this case, the panel 50 is capable of expressing a wide range of designs while taking advantage of the glossiness of the metal substrate 55. In the panel 50 using the metal substrate 55, a unique design is created by taking advantage of the glossiness of the metal substrate 55, and by utilizing this unique design, the range of design expression can be expanded. In other words, design expression that takes advantage of the natural characteristics of the metal substrate 55, more specifically, metallic design expression in which the lightness, saturation, and hue change significantly depending on the observation angle, becomes possible.

[0074] When the design layer 56 contains an organic colorant, it is possible to achieve a design expression with high brightness and saturation (diverse color expression) without excessively concealing the glossiness of the metal substrate 55. Specifically, it is possible to reproduce design expressions such as brass, copper, corrosion patterns, and polished patterns at a higher level than ever before. Furthermore, when the flop index on the first surface 50a is 4.5 or higher, the glossiness of the metal substrate 55 can be fully utilized. Conventional color difference evaluation is significantly affected by the glossiness of the surface of the panel 50, making it difficult to quantitatively evaluate the glossiness of the metal substrate 55. In contrast, in the present embodiment, by focusing on the flop index, it is possible to quantitatively evaluate the glossiness of the metal substrate 55 without being significantly affected by the glossiness of the surface of the panel 50.

[0075] 1. Flop Metrics As shown in FIG. 9, the panel 50 in this embodiment may have a region on the first surface 50a located on the side of the design layer 56 with respect to the metal base material 55, where the flop index is 4.5 or more.

[0076] The glossiness of the metal substrate 55 varies greatly in brightness, saturation, and hue depending on the position and angle of light reception and observation. The characteristic of this change is called flop, and the flop index is an index that quantitatively evaluates the flop. The flop index is calculated by dividing the L at effective angles of 15°, 45°, and 110°. * (L* 15 , L * 45 , L * 110 ) is calculated using the following formula: Flop Index = 2.69 × (L * 15 -L * 110 ) 1·11 / (L * 45 ) 0·85 The method for measuring the flop index will be described in detail in the examples below.

[0077] The flop index in the above region may be 5 or more, 6 or more, 7 or more, or 8 or more. In addition, when viewed in the thickness direction, the above region is usually a region containing an organic colorant.

[0078] When the panel 50 is viewed from the side of the design layer 56, the area of ​​the design layer 56 is S A Let the area of ​​the above region be S B Let's say S A S against B The ratio (S B / S A ) is, for example, 1% or more, may be 3% or more, or may be 5% or more. B / S A Although it depends on the design of the design layer 56, it may be 100% or less. In the latter case, the design will have an area that makes the most of the glossiness of the metal base material 55 and an area that does not make the most of the glossiness of the metal base material 55. S B / S A may be 80% or less, or may be 60% or less.

[0079] 2. Design layer The design layer 56 in this embodiment is a layer that imparts design to the panel 50 and contains an organic colorant. The design layer 56 may be a design layer having a design (pattern) and may also be referred to as a surface design layer. The design layer 56 may be a solid layer (a layer coated with ink) or a combination of a design layer and a solid layer.

[0080] Examples of patterns in the design layer include wood grain patterns, marble patterns, stone patterns, sand patterns, tile patterns, brickwork patterns, fabric patterns, leather-striped patterns, geometric shapes, letters, symbols, abstract patterns, floral patterns, wave patterns, striped patterns, metallic patterns, and rust-like patterns.

[0081] The design layer 56 contains an organic colorant (organic pigment or organic dye). Examples of the organic colorant include perylene-based colorants, cyanine-based colorants, nickel-azo complex-based colorants, azomethine-based colorants, quinacridone-based colorants, and isoindolinone-based colorants.

[0082] The average particle size of the organic colorant is, for example, from 100 μm to 350 μm, and may be from 200 μm to 300 μm. In this specification, the average particle size refers to the 50% particle size (d50: median diameter) when the particle size distribution measured by a dynamic light scattering method is expressed as a cumulative volume distribution. Furthermore, the content of the organic colorant in the layer containing the organic colorant is, for example, from 1 part by mass to 40 parts by mass per 100 parts by mass of the resin component.

[0083] On the other hand, the design layer 56 may contain an inorganic colorant (inorganic pigment or inorganic dye). Examples of inorganic colorants include carbon black, iron black, titanium white, antimony white, titanium yellow, yellow iron oxide, red iron oxide, cadmium red, ultramarine blue, and cobalt blue. The design layer 56 may also contain metallic colorants such as aluminum and brass; or pearl colorants such as titanium dioxide-coated mica and basic lead carbonate.

[0084] The design layer 56 contains a resin. The resin contained in the design layer 56 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. Examples of resins contained in the design layer 56 include fluorine-based resins, epoxy-based resins, phenol-based resins, urea-based resins, polyester-based resins, melamine-based resins, alkyd-based resins, amide-based resins, polyimide-based resins, silicone-based resins, acrylic-based resins, urethane-based resins, urethane-acrylic resins, styrene-based resins, and cellulose-based resins. Among these, fluorine-based resins are preferred as the curable resin because they have good weather resistance. Examples of fluorine-based resins include fluoroethylene-vinyl ether copolymers, fluoroethylene-vinyl ester copolymers, and fluoroethylene-acrylic copolymers.

[0085] The resin contained in the design layer 56 may be a cured product of a resin composition containing a curable resin and a curing agent. Examples of the curing agent include isocyanate compounds such as tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), and xylylene diisocyanate (XDI). The ratio of the curing agent to 100 parts by mass of the curable resin is not particularly limited, but may be, for example, 30 parts by mass or more and 70 parts by mass or less, or 35 parts by mass or more and 65 parts by mass or less. The design layer 56 may also contain additives such as a weathering agent. Details of the weathering agent will be described later.

[0086] The design layer 56 may have a single layer structure or a laminated structure of two or more layers. The design layer 56 preferably has a pattern layer containing an organic colorant. The pattern layer containing an organic colorant may be one layer or two or more layers. The design layer 56 may also have a solid layer containing an organic colorant. The solid layer containing an organic colorant may be one layer or two or more layers. The design layer 56 has at least a layer containing an organic colorant, but may also have a layer containing an inorganic colorant. The layer containing an inorganic colorant may be a pattern layer containing an inorganic colorant, a solid layer containing an inorganic colorant, or both. The pattern layer containing an inorganic colorant and the solid layer containing an inorganic colorant may each be one layer or two or more layers.

[0087] The design layer 56 may have, in the thickness direction from the metal substrate 55 side, a layer containing an inorganic colorant and a layer containing an organic colorant, in this order. The layer containing an inorganic colorant and the layer containing an organic colorant may each independently be a solid layer or a pattern layer. For example, by providing a solid layer containing an inorganic colorant, the color of the metal substrate 55 can be adjusted. Alternatively, by overlapping a pattern layer containing an inorganic colorant with a pattern layer containing an organic colorant, the layer containing the organic colorant can maintain the glossiness of the metal substrate 55, while the layer containing the inorganic colorant can provide a partial concealing area, thereby enabling complex design expression.

[0088] Similarly, the design layer 56 may have, in the thickness direction from the metal substrate 55 side, a layer containing an organic colorant and a layer containing an inorganic colorant, in this order. In this case, the layer containing the organic colorant and the layer containing the inorganic colorant may each independently be a solid layer or a pattern layer. The design layer 56 may also have a layer containing both an organic colorant and an inorganic colorant. Note that the design layer 56 does not necessarily have a layer containing an inorganic colorant.

[0089] The design layer 56 is preferably a baked layer. A baked layer is a layer formed by heat-curing (baking) a coated composition, and is a layer different from the design layer 56 that is attached via an adhesive layer, for example. The thickness of the design layer 56 is not particularly limited, but may be, for example, 1 μm or more and 10 μm or less, or 3 μm or more and 7 μm or less. When the design layer 56 has multiple layers, the total thickness of the multiple layers is preferably within the above range.

[0090] 3.Metal base material The metal base 55 in this embodiment is a base material containing a metal element. Examples of the metal element contained in the metal base 55 include aluminum, iron, copper, and titanium. The metal base 55 preferably contains the above-mentioned metal element as a main component.

[0091] The metal substrate 55 may be a simple metal containing one type of metal element, or an alloy containing two types of metal elements. The metal substrate 55 may also contain a carbon component. Specific examples of the metal substrate include an aluminum substrate, an aluminum alloy substrate (e.g., a duralumin substrate), a steel substrate (a steel substrate), a stainless steel substrate, a copper substrate, a copper alloy substrate (e.g., a brass substrate, a bronze substrate), a titanium substrate, and a titanium alloy substrate. The surface of the metal substrate may be plated.

[0092] In particular, it is preferable that the metal base material 55 is an Al-Mn alloy. An Al-Mn alloy is an aluminum alloy that is made by adding mainly Mn (manganese) to increase the strength of pure aluminum. An Al-Mn alloy may also be called an aluminum-manganese alloy or a 3000-series aluminum alloy. When the metal base material 55 is an Al-Mn alloy, it becomes possible to bake the design layer 56 onto the metal base material 55 at a high temperature, as will be described later. Baking the design layer 56 at a high temperature improves the weather resistance of the panel 50.

[0093] The metal base material 55 may be bent. The thickness of the metal base material 55 is, for example, 1.0 mm or more, 1.2 mm or more, 1.5 mm or more, or 1.7 mm or more. The thickness of the metal base material 55 is, for example, 5.0 mm or less, 4.0 mm or less, or 3.0 mm or less. When the thickness of the metal base material 55 is 1.0 mm or more, the metal base material 55 is sufficiently thick so that the stud bolts 36 described above can be welded to the metal base material 55 so as to protrude toward the surface opposite the design layer 56. In this case, the metal base material 55 is sufficiently thick so that substantially no trace of the stud bolts 36 fixed to the metal base material 55 appears on the design layer 56 side. This prevents the design of the design layer 56 from being impaired by the traces of the stud bolts 36.

[0094] 4. Primer layer The panel 50 in this embodiment may have a primer layer 57 between the metal substrate 55 and the design layer 56. By providing the primer layer 57, the adhesion between the two layers adjacent to the primer layer 57 is improved.

[0095] The primer layer 57 contains a resin. The resin contained in the primer layer 57 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a thermosetting resin. Examples of resins contained in the primer layer 57 include urethane-based resins, acrylic polyol-based resins, acrylic resins, ester-based resins, amide-based resins, butyral-based resins, styrene-based resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer main chain and two or more hydroxyl groups at the terminals and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene-based resins, nitrocellulose-based resins (nitrocellulose), cellulose acetate-based resins, and fluorine-based resins.

[0096] The resin contained in the primer layer 57 may be a cured product of a resin composition containing a curable resin and a curing agent. Examples of the curing agent include isocyanate compounds such as tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), and xylylene diisocyanate (XDI). The primer layer 57 may also contain additives such as weathering agents. Details of weathering agents will be described later.

[0097] The primer layer 57 is preferably a baked layer. The thickness of the primer layer 57 is not particularly limited, but may be, for example, 1 μm or more and 10 μm or less, or 2 μm or more and 5 μm or less.

[0098] 5. Base layer The panel 50 in this embodiment may have a base layer 58 between the metal base material 55 and the design layer 56. For example, by providing the base layer 58, it is possible to adjust the glossiness of the metal base material 55. In order to make the most of the glossiness of the metal base material 55, the base layer 58 is usually a transparent layer (colored transparent or colorless transparent).

[0099] The base layer 58 contains a resin. The resin contained in the base layer 58 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. The curable resin is preferably a fluorine-based resin, as this has good weather resistance. The base layer 58 may or may not contain a colorant. The base layer 58 may also contain an inorganic colorant. The curable resin and colorant are the same as the curable resin used in the design layer 56 described above, and therefore a description thereof will be omitted here. The base layer 58 may also contain an additive such as a weather resistant agent. Details of the weather resistant agent will be described later.

[0100] The underlayer 58 is preferably a baked layer. The thickness of the underlayer 58 is not particularly limited, but may be, for example, 5 μm or more and 40 μm or less, or 10 μm or more and 30 μm or less.

[0101] 6.Surface protection layer The panel 50 in the present embodiment may have a surface protective layer 59 on the opposite side of the design layer 56 from the metal base material 55. By providing the surface protective layer 59, for example, the scratch resistance of the panel 50 is improved.

[0102] The surface protective layer 59 contains a resin. The resin contained in the surface protective layer 59 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. The curable resin is preferably a fluorine-based resin, as this has good weather resistance. The surface protective layer 59 may also contain a colorant. The curable resin and colorant are the same as the curable resin used in the design layer 56 described above, and therefore a description thereof will be omitted here.

[0103] The surface protective layer 59 may contain one or more types of fillers. An example of the filler is an organic filler. Examples of the organic filler include resin fillers such as acrylic resins, urethane resins, nylon resins, olefin resins, and urea resins. Among these, acrylic resin fillers (acrylic beads) are preferred. This is because acrylic resin fillers have good heat resistance and are less restricted in terms of production. On the other hand, another example of the filler is an inorganic filler. Examples of inorganic fillers include silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, and synthetic silicates.

[0104] The average particle size of the filler is, for example, 5 μm or more and 60 μm or less, or may be 10 μm or more and 50 μm or less, or may be 20 μm or more and 40 μm or less.

[0105] The surface protective layer 59 preferably contains a weather-resistant agent. Since the organic colorants contained in the design layer 56 generally have low weather resistance, while inorganic colorants have low weather resistance, it is preferable that the surface protective layer 59 have sufficient weather resistance. Examples of the weather-resistant agent include an ultraviolet absorber and a light stabilizer.

[0106] Examples of the ultraviolet absorber include organic ultraviolet absorbers such as triazine-based ultraviolet absorbers, benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, oxybenzophenone-based ultraviolet absorbers, salicylic acid ester-based ultraviolet absorbers, and cyano(meth)acrylate-based ultraviolet absorbers, and inorganic ultraviolet absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based ultraviolet absorbers are preferred.

[0107] Examples of triazine-based ultraviolet absorbers include hydroxyphenyltriazine-based ultraviolet absorbers. Examples of hydroxyphenyltriazine-based ultraviolet absorbers include 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2,4-bis[2-hydroxy-4-butoxyphenyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine, azine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5[2-(2-ethylhexanoyloxy)ethoxy]phenol.

[0108] The content of the ultraviolet absorber in the surface protective layer 59 is, for example, 0.5 parts by mass to 10 parts by mass, alternatively 0.8 parts by mass to 8 parts by mass, or alternatively 1 part by mass to 5 parts by mass, relative to 100 parts by mass of the resin component. If the content of the ultraviolet absorber is too high, bleeding out of the ultraviolet absorber may occur, whereas if the content of the ultraviolet absorber is too low, sufficient ultraviolet absorption performance may not be obtained.

[0109] On the other hand, examples of the light stabilizer include hindered amine light stabilizers. Examples of the hindered amine light stabilizer include 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, methyl(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine).

[0110] The content of the light stabilizer in the surface protective layer 59 is, for example, 1 part by mass to 10 parts by mass, or alternatively 1.5 parts by mass to 8 parts by mass, or alternatively 2 parts by mass to 5 parts by mass, relative to 100 parts by mass of the resin component. If the content of the light stabilizer is too high, bleeding out of the light stabilizer may occur, and if the content of the light stabilizer is too low, sufficient light stability may not be obtained.

[0111] The surface protection layer 59 is preferably a baked layer. The thickness of the surface protection layer 59 is not particularly limited, but may be, for example, from 5 μm to 40 μm, or from 10 μm to 30 μm.

[0112] 7. Panel The panel 50 in this embodiment has a metal base material 55 and a design layer 56, in this order in the thickness direction. The panel 50 may further have at least one of the above-mentioned primer layer 57, underlayer 58, and surface protection layer 59. The layer structure of the panel 50 in this embodiment is not particularly limited, but examples include the following layer structures. The symbol " / " indicates the boundary between layers. Furthermore, the two components separated by the symbol " / " may be arranged in direct contact with each other, or may be arranged with another component interposed therebetween.

[0113] (1) Metal substrate 55 / design layer 56 (2) Metal substrate 55 / primer layer 57 / design layer 56 (3) Metal substrate 55 / base layer 58 / design layer 56 (4) Metal substrate 55 / primer layer 57 / undercoat layer 58 / design layer 56 (5) Metal substrate 55 / design layer 56 / surface protective layer 59 (6) Metal substrate 55 / primer layer 57 / design layer 56 / surface protective layer 59 (7) Metal substrate 55 / base layer 58 / design layer 56 / surface protective layer 59 (8) Metal substrate 55 / primer layer 57 / undercoat layer 58 / design layer 56 / surface protective layer 59

[0114] The panel 50 in this embodiment may have a plurality of protrusions (raised portions) on the first surface located on the side of the design layer 56 relative to the metal substrate 55. The protrusions preferably contain at least one of a filler and a colorant, and a binder resin that aggregates at least one of the filler and the colorant. The type of colorant is not particularly limited, but examples include pearlescent colorants. The average height of the protrusions is, for example, 10 μm to 60 μm, or may be 15 μm to 45 μm, or 25 μm to 35 μm. The average height of the protrusions is determined, for example, as the arithmetic mean of the heights of 100 or more protrusions.

[0115] The weather resistance of panel 50 can be measured by an accelerated weathering test using a sunshine weather meter. Specifically, panel 50 is subjected to an accelerated weathering test using a sunshine weather meter. In this case, when the total ultraviolet irradiation time reaches 10,000 hours, the color difference (ΔE) before and after the accelerated weathering test may be 7 or less, 5 or less, or 3 or less. Details of the accelerated weathering test will be described in the examples below.

[0116] B. Panel manufacturing method FIG. 11 is a schematic cross-sectional view illustrating a manufacturing method of a panel 50 according to the present embodiment. First, as shown in FIG. 11(a), a metal substrate 55 is prepared (metal substrate preparation step). Next, as shown in FIG. 11(b), a primer layer 57 is formed on one surface of the metal substrate 55 (primer layer formation step). Next, as shown in FIG. 11(c), a base layer 58 is formed on the surface of the primer layer 57 opposite the metal substrate 55 (base layer formation step). Next, as shown in FIG. 11(d), a composition containing an organic colorant is applied to the surface of the base layer 58 opposite the primer layer 57, and the applied composition is heat-cured to form a design layer 56 (design layer formation step). Next, as shown in FIG. 11(e), a surface protection layer 59 is formed on the surface of the design layer 56 opposite the base layer 58 (surface protection layer formation step). This completes the manufacturing process of the panel 50.

[0117] 1.Metal base material preparation process The method for manufacturing a panel in this embodiment includes a metal base material preparation step of preparing a metal base material 55. The metal base material 55 is the same as that described above in "A. Panel."

[0118] 2.Primer layer formation process The manufacturing method of panel 50 in this embodiment may include a primer layer forming step of forming primer layer 57 on one surface of metal base material 55. In the primer layer forming step, primer layer 57 may be formed directly on one surface of metal base material 55, or may be formed via another layer.

[0119] The primer layer 57 can be formed, for example, by applying a composition for the primer layer 57 and then heat-curing it. Examples of methods for applying the composition include roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the primer layer 57 is formed, for example, over the entire surface of the metal substrate 55. The heating temperature (substrate temperature) is, for example, 100°C or higher and 300°C or lower.

[0120] 3. Base layer formation process The panel manufacturing method in this embodiment may include a base layer forming step of forming a base layer 58 on one surface of the metal base material 55. In the base layer forming step, the base layer 58 may be formed directly on one surface of the metal base material 55, or may be formed via another layer such as the primer layer 57 described above.

[0121] The base layer 58 can be formed, for example, by applying a composition for the base layer 58 and then heat-curing it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the base layer 58 is formed, for example, so as to cover the entire surface of the metal substrate 55. The heating temperature (substrate temperature) is, for example, 150°C or higher and 300°C or lower, and may be 200°C or higher and 250°C or lower.

[0122] 4. Design layer formation process The manufacturing method of panel 50 in this embodiment includes a design layer forming step of applying a composition containing an organic colorant to one surface of metal substrate 55 and heat-curing it to form design layer 56. In the design layer forming step, design layer 56 may be formed directly on one surface of metal substrate 55, or may be formed via another layer such as primer layer 57 or undercoat layer 58 described above.

[0123] The design layer 56 can be formed, for example, by applying a composition for the design layer 56 and then heat-curing it. Examples of methods for applying the composition include gravure printing, offset printing, gravure-offset printing, flexographic printing, letterpress printing, screen printing, inkjet printing, and transfer printing. When viewed in the thickness direction, the design layer 56 may be formed so as to cover the entire surface of the metal substrate 55, or may be formed so as to cover a portion of the metal substrate 55. The heating temperature (substrate temperature) may be, for example, 150°C to 300°C, or 200°C to 250°C. Furthermore, when a process for forming another layer, such as the surface protection layer 59 described below, is performed as a later process, the heat-curing process for forming the design layer 56 may be performed before the later process or simultaneously with the heat-curing process for forming the other layer in the later process.

[0124] As described above, the panel 50 in this embodiment may include a metal base material 55 containing an Al-Mn alloy. The metal base material 55 containing an Al-Mn alloy has greater strength than a typical aluminum plate. This allows the decorative layer 56 to be baked onto the metal base material 55 at a higher temperature, thereby improving the weather resistance of the panel 50.

[0125] 5.Surface protective layer formation process The manufacturing method of panel 50 in this embodiment may include a surface protective layer forming step of forming surface protective layer 59 on the surface of design layer 56 opposite metal substrate 55. In the surface protective layer forming step, surface protective layer 59 may be formed directly on the surface of design layer 56 opposite metal substrate 55, or may be formed via another layer.

[0126] The surface protective layer 59 can be formed, for example, by applying a composition for the surface protective layer 59 and then heat-curing it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the surface protective layer 59 is formed so as to cover the entire surface of the metal substrate 55. The heating temperature (substrate temperature) may be, for example, 150°C or higher and 300°C or lower, or 200°C or higher and 250°C or lower.

[0127] 6. Panel The panel obtained by each of the above steps is the same as that described above in "A. Panel."

[0128] [Example] Next, a specific example of the panel according to this embodiment will be described.

[0129] [Example 1-1] An aluminum plate (A3004PH32, dimensions: 300 mm × 600 mm, thickness: 1.0 mm, chromate-treated) was prepared as a metal substrate. Next, as a pretreatment, the prepared aluminum plate was washed with hot water and then dried at 150°C (the temperature reached by the substrate).

[0130] Next, the following composition for the undercoat layer was applied to the entire surface of the aluminum plate using a curtain flow coater so that the film thickness after drying would be 18 μm, and then baked at 216°C (the temperature reached by the substrate) to form the undercoat layer.

[0131] (Undercoat layer composition) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Gray colorant (titanium oxide, chromium oxide; 5% by mass based on thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 17% by mass

[0132] Next, the composition for the design layer described below was applied to the entire surface of the undercoat layer by gravure offset printing so that the film thickness after drying would be 0.5 μm or more and 15 μm or less.

[0133] (Composition for design layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Organic colorant (a blend of three colors: perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 15% by mass based on the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0134] Next, the entire surface of the design layer was coated with the following composition A for the surface protective layer using a bar coater so that the film thickness after drying was 19 μm. Then, the coating was baked at 224 ° C (substrate temperature) to form a surface protective layer, and a panel was obtained. The obtained surface protective layer is referred to as surface protective layer A.

[0135] (Composition A for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0136] [Example 1-2] Except that the following composition B for the surface protective layer was used instead of composition A for the surface protective layer. A panel was obtained in the same manner as in Example 1-1. The obtained surface protective layer is referred to as surface protective layer B.

[0137] (Surface protective layer composition B) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0138] [Examples 1-3] A panel was obtained in the same manner as in Example 1-1, except that the following composition C for the surface protective layer was used instead of the composition A for the surface protective layer. The obtained surface protective layer is referred to as surface protective layer C.

[0139] (Surface protective layer composition C) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 10 μm, 4% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 30 μm, 2% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 11, mass ratio) Solid content concentration: 30% by mass

[0140] [Examples 1-4] A panel was obtained in the same manner as in Example 1-1, except that the following composition D for the surface protective layer was used instead of the composition A for the surface protective layer. The obtained surface protective layer is referred to as surface protective layer D.

[0141] (Surface protective layer composition D) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 30 μm, 4% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 50 μm, 2% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 11, mass ratio) Solid content concentration: 30% by mass

[0142] [Examples 2-1 to 2-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a perylene pigment (red) was used as the organic colorant contained in the composition for the design layer.

[0143] [Examples 3-1 to 3-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a cyanine pigment (blue) was used as the organic colorant contained in the composition for the design layer.

[0144] [Examples 4-1 to 4-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a nickel azo complex pigment (yellow) was used as the organic colorant contained in the composition for the design layer.

[0145] [Comparative Examples 1-1 to 1-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that an inorganic colorant (a three-color blend of iron oxide pigment (red), cobalt pigment (blue), and iron oxide pigment (yellow)) was used instead of the organic colorant contained in the composition for the design layer.

[0146] [Comparative Examples 2-1 to 2-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that an iron oxide pigment (red) was used instead of the organic colorant contained in the composition for the design layer.

[0147] [evaluation] The flop index was measured using the panels obtained in each Example and Comparative Example. Specifically, the panel was placed horizontally with the surface protective layer facing up, and the lightness index L was measured using a three-dimensional goniospectrophotometric colorimeter (manufactured by Murakami Color Research Laboratory, model number GCMS-4). * The measurement conditions were an incident angle of 45°, tilt angle of 0°, in-plane rotation angle of 0°, light source D65, and L at receiving angles of 30°, 0°, and -65°. * The flop index was then calculated using the following formula. The results are shown in Tables 1 and 2. Flop Index = 2.69 × (L *15 -L * 110 ) 1·11 / (L * 45 ) 0·85 (L * 15 is L at an acceptance angle of 30° * This applies to L * 45 is L at 0° acceptance angle * This applies to L * 110 is L at an acceptance angle of -65° * (corresponding to

[0148] [Table 1]

[0149] [Table 2]

[0150] As shown in Table 1, in each example, the flop index was high, and it was confirmed that the glossiness of the metal substrate was well expressed. Furthermore, because an organic colorant was used, it was possible to suppress concealment of the glossiness by the design layer while still achieving a vivid design expression. In contrast, as shown in Table 2, in each comparative example, the flop index was low, and it was confirmed that the glossiness of the metal substrate was not well expressed. This is presumably because the use of an inorganic colorant resulted in significant concealment of the glossiness by the design layer.

[0151] Fig. 12 is a graph showing the results of Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. The triangles in Fig. 12 represent the flop indexes of samples prepared in the same manner as Examples 1-1 to 1-4 except that no design layer was formed, and the same applies to the triangles in Figs. 13 to 15 described below. As shown in Fig. 12, Examples 1-1 to 1-4 had higher flop indexes than Comparative Examples 1-1 to 1-4, confirming that the glossiness of the metal substrate was well expressed. Furthermore, a comparison of Examples 1-1 to 1-4 confirmed that the flop index was less affected by the glossiness of the first surface (the surface of the surface protective layer), confirming that the glossiness of the metal substrate could be accurately evaluated.

[0152] Fig. 13 is a graph showing the results of Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. As shown in Fig. 13, Examples 2-1 to 2-4 had a higher flop index than Comparative Examples 2-1 to 2-4, confirming that the glossy feel of the metal substrate was well expressed. Fig. 14 is a graph showing the results of Examples 3-1 to 3-4, and Fig. 15 is a graph showing the results of Examples 4-1 to 4-4. As shown in Figs. 14 and 15, Examples 3-1 to 3-4 and Examples 4-1 to 4-4 had a high flop index, confirming that the glossy feel of the metal substrate was well expressed.

[0153] [Example 5-1] First, a base layer was formed on the entire surface of an aluminum plate in the same manner as in Example 1-1. Next, the first composition for the design layer described below was applied to the entire surface of the base layer by gravure offset printing so that the film thickness after drying would be 0.5 μm or more and 1.5 μm or less, to form an inorganic colorant layer.

[0154] (First composition for design layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Inorganic colorant (carbon black; 4% by mass based on thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid concentration: 15% by mass

[0155] Next, the second composition for the design layer described below was applied to the entire surface of the inorganic colorant layer by gravure offset printing so that the film thickness after drying would be 0.5 μm to 1.5 μm, thereby forming an organic colorant layer, thereby obtaining a design layer having an inorganic colorant layer and an organic colorant layer.

[0156] (Second composition for design layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Organic colorant (a blend of three colors: perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 15% by mass based on the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0157] Next, a surface protective layer A was formed on the entire surface of the design layer in the same manner as in Example 1-1, to obtain a panel.

[0158] [Examples 5-2 to 5-4] Each panel was obtained in the same manner as in Example 5-1, except that only perylene-based pigment (red), only cyanine-based pigment (blue), or only nickel azo complex-based pigment (yellow) was used as the organic colorant contained in the second composition for the design layer.

[0159] [Comparative Example 3-1] A panel was obtained in the same manner as in Example 5-1, except that the organic colorant layer was not formed.

[0160] [Comparative Example 3-2] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition B for the surface protective layer was used instead of composition A for the surface protective layer.

[0161] [Comparative Example 3-3] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition C for the surface protective layer was used instead of composition A for the surface protective layer.

[0162] [Comparative Example 3-4] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition D for the surface protective layer was used instead of composition A for the surface protective layer.

[0163] [evaluation] The flop index was measured using the panels obtained in Examples 5-1 to 5-4 and Comparative Examples 3-1 to 3-4. The measurement method was the same as above. The results are shown in Tables 3 and 4.

[0164] [Table 3]

[0165] [Table 4]

[0166] As shown in Tables 3 and 4, it was confirmed that Examples 5-1 to 5-4, which had an organic colorant layer, had a high flop index similar to Comparative Examples 3-1 to 3-4, which did not have an organic colorant layer. In other words, it was confirmed that the organic colorant layer had limited ability to conceal glossiness, and that the organic colorant layer enabled vivid design expression.

[0167] [Examples 6-1 to 6-3] Panels were obtained in the same manner as in Example 2-1, Example 3-1, and Example 4-1, respectively, except that the following composition X for the base layer was used as the composition for the base layer, and the following composition A2 for the surface protective layer was used instead of the composition A for the surface protective layer.

[0168] (Composition X for base layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Gray colorant (titanium oxide, chromium oxide; 5% by mass based on thermosetting fluororesin) UV absorbers Hindered amine light stabilizers Solid content concentration: 17% by mass

[0169] (Surface protective layer composition A2) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) UV absorbers Hindered amine light stabilizer solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0170] [evaluation] The weather resistance of the panels obtained in Examples 6-1 to 6-3 was evaluated. The obtained panels were subjected to an accelerated weather resistance test using a Sunshine Weather Meter (SWOM). Specifically, under the following irradiation conditions, the panels were irradiated for 102 minutes, followed by irradiating and spraying for 18 minutes, totaling 120 minutes, and this cycle was repeated until the total ultraviolet irradiation time was 10,000 hours.

[0171] <Conditions for accelerated weathering test> (Test equipment) Suga Testing Machinery, product name "S80" (Irradiation conditions) Illuminance: 255W / m 2 , Black panel temperature: 65℃, chamber humidity: 5096RH, time: 102 minutes of irradiation, followed by 18 minutes of irradiation and spraying

[0172] The weather resistance of the panels was evaluated by color difference and gloss retention. Regarding color difference, the color difference (ΔE) value before and after the accelerated weathering test was measured using a spectrophotometer (Konica Minolta CM-5 spectrophotometer). Regarding gloss retention, the 60° gloss value of the surface protective layer was measured using a gloss meter in accordance with JIS K5600. The 60° gloss value was calculated as the average of the measurements at 10 locations. The results are shown in Table 5.

[0173] [Table 5]

[0174] As shown in Table 5, Examples 6-1 to 6-3 were confirmed to have small color difference (ΔE), high gloss retention, and good weather resistance. Organic colorants are known to have lower weather resistance than inorganic colorants, but Examples 6-1 to 6-3 used organic colorants to obtain panels that can also be used as exterior components.

[0175] [Example 7] An aluminum plate (A3004PH32, dimensions: 300 mm × 600 mm, thickness: 1.0 mm, chromate-treated) was prepared as the metal substrate. Next, as a pretreatment, the prepared aluminum plate was washed with hot water, coated with a polyester primer, and then dried at 200°C (the temperature reached by the substrate).

[0176] Next, the following composition for the undercoat layer was applied to the entire surface of the aluminum plate using a curtain flow coater so that the film thickness after drying would be 18 μm, and then baked at 216°C (the temperature reached by the substrate) to form the undercoat layer.

[0177] (Undercoat layer composition) Thermosetting polyester resin Solvent (xylene:cyclohexanone = 1:1) Solid content concentration: 40% by mass

[0178] Next, the composition for the design layer described below was applied to the entire surface of the undercoat layer by gravure offset printing so that the film thickness after drying would be 0.5 μm or more and 15 μm or less.

[0179] (Composition for design layer) Thermosetting polyester resin organic colorant (a three-color blend of perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 7.5% by mass based on the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0180] Next, the composition for the surface protection layer described below was applied to the entire surface of the design layer using a bar coater so that the film thickness after drying would be 22 μm, and then baked at 224 ° C (the temperature reached by the substrate) to form a surface protection layer, thereby obtaining a panel.

[0181] (Surface protection layer composition) Thermosetting polyester resin UV absorbers Hindered amine light stabilizers Filler (silica, average particle size 2 μm; 3% by mass relative to thermosetting polyester resin) Solvent (xylene:cyclohexanone = 1:1) Solid content concentration: 42% by mass

[0182] The weather resistance of the obtained panel was evaluated in the same manner as above. As a result, the color difference (ΔE) and gloss retention were maintained to a certain extent until the ultraviolet irradiation time reached 500 hours, but when the ultraviolet irradiation time reached 1000 hours, the color difference (ΔE) became 4.3 and the gloss retention became 10%. Comparing Example 7 with Examples 6-1 to 6-3, it was confirmed that the weather resistance was significantly improved by using a fluorine-based resin as the thermosetting resin.

[0183] It is also possible to combine the multiple components disclosed in the above embodiments and modifications as needed, or to delete some of the components disclosed in the above embodiments and modifications. [Explanation of symbols]

[0184] 10 Partition 20 frames 21 Bottom frame 22 Upper frame 23 Outer Frame 24 Inner Frame 30 Kick-off board 50 panels 51 Main surface members 52 Top surface member 53 Exterior components 55 Metal base material 56 Design Layer 90 Buildings

Claims

1. At the partition, The frame and a panel attached to the frame; The panel includes a metal substrate containing an Al-Mn alloy and a design layer laminated on the metal substrate, the panel is disposed on the outside of the frame so as to cover the frame; The panel has a main surface member, a top surface member, and an outer surface member, and the top surface member and the outer surface member are each bent relative to the main surface member.

2. At the partition, The frame and a panel attached to the frame; The panel includes a metal substrate and a design layer laminated on the metal substrate, A stud bolt is fixed to the panel, the panel is attached to the frame by the stud bolts; the panel is disposed on the outside of the frame so as to cover the frame; The panel has a main surface member, a top surface member, and an outer surface member, and the top surface member and the outer surface member are each bent relative to the main surface member.

3. 3. The partition plate according to claim 1, wherein the metal substrate has a thickness of 1.0 mm or more.

4. The partition plate according to claim 1 , wherein stud bolts are fixed to the panel, and the panel is attached to the frame by the stud bolts.

5. 5. The separator of claim 2 or 4, wherein the stud bolt comprises aluminum or steel.

6. The partition plate according to claim 1 or 2, further comprising a kick-off plate held by the frame.

7. The partition plate according to claim 1 or 2, wherein the frame has a lower frame, an upper frame, an outer frame, and an inner frame, the outer frame has an outer groove portion, and the outer groove portion contains a decorative material.

8. The partition plate according to claim 1 or 2, wherein the panel has a region on a first surface located on the decorative layer side with respect to the metal base material, the region having a flop index of 4.5 or more.

9. The partition plate according to claim 1 or 2, wherein the decorative layer contains an organic colorant.

10. The partition plate according to claim 1 or 2, wherein the decorative layer is a baked layer.

11. 3. The partition according to claim 1 or 2, wherein the panel is subjected to an accelerated weathering test using a sunshine weather meter, and when the ultraviolet irradiation time reaches a total of 10,000 hours, the color difference (ΔE) before and after the accelerated weathering test is 7 or less.

12. A partition panel having a frame, the partition panel being attached to the outside of the frame so as to cover the frame, a metal substrate containing an Al—Mn-based alloy; A design layer laminated on the metal substrate, The panel has a main surface member, a top surface member, and an outer surface member, The top surface member and the outer surface member are each folded relative to the main surface member.

13. The panel according to claim 12, further comprising a stud bolt for attaching the partition plate to the frame, the stud bolt being fixed so as to protrude toward the surface of the metal base opposite the decorative layer.

14. A building comprising the partition plate according to claim 1 or 2.

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