Method for manufacturing wallpaper panel, wallpaper panel, and method for installing wallpaper panel

Abstract

A method for manufacturing a wallpaper panel 1 according to the present disclosure comprises: a step A for applying an adhesive to a wallpaper 10 or a base material 20 by means of a coating mechanism; and a step B for crimping the wallpaper 10 to the front surface 20A of the base material 20 by means of a crimping mechanism, wherein the wallpaper 10 has a backing material, and any of plain paper, flame retardant paper, inorganic paper, woven fabric, or non-woven fabric is used as the backing material.

Description

Wallpaper panel manufacturing method, wallpaper panel, and wallpaper panel installation method

[0001] The present disclosure relates to a method for manufacturing a wallpaper panel, a wallpaper panel, and a method for installing the wallpaper panel.

[0002] BACKGROUND ART A conventional wall construction method is known in which a craftsman fixes a gypsum board to a stud or beam with screws, and then pastes wallpaper so as to hide the screws that fix the gypsum board.

[0003] WO2023 / 112478A1

[0004] However, conventional wall construction methods have the drawback of requiring skilled workers to paste wallpaper onto gypsum boards at the construction site. Also, there is a need for a solution to deal with the shortage of skilled workers.

[0005] Therefore, the present disclosure has been made in consideration of the above-mentioned problems, and aims to provide a method for manufacturing a wallpaper panel, a wallpaper panel, and a method for installing a wallpaper panel that do not require the work of pasting wallpaper onto gypsum board at the installation site.

[0006] A first feature of the present disclosure is a method for manufacturing a wallpaper panel including a base material and wallpaper having a front, back, top, bottom, left side, and right side, the method comprising: a step A of applying adhesive to the wallpaper or the base material by an application mechanism; and a step B of pressing the wallpaper onto the front side of the base material by a pressing mechanism, the wallpaper having a backing material, and the backing material being any of ordinary paper, flame-retardant paper, inorganic paper, woven fabric, and nonwoven fabric.

[0007] A second feature of the present disclosure is a wallpaper panel including wallpaper and a base material, wherein the base material has a front, a back, a top, a bottom, a left side, and a right side, the wallpaper has a backing material, and the backing material is made of any of ordinary paper, flame-retardant paper, inorganic paper, woven fabric, and non-woven fabric, the wallpaper is attached to the base material with an adhesive so as to cover the front, and the wallpaper is attached to the base material by a lamination method.

[0008] A third feature of the present disclosure is a method for installing a wallpaper panel (a wallpaper panel having the second feature described above), which includes a step C of applying an adhesive or glue to a member to which the wallpaper panel is attached, a step D of temporarily fixing a portion of the back surface of a base material for the wallpaper panel to the adhesive or glue, and a step E of pressing the wallpaper panel.

[0009] A fourth feature of the present disclosure is a method for installing wallpaper panels, comprising the steps of: acquiring identification information assigned to wallpaper; acquiring a wallpaper panel associated with the identification information; attaching the acquired wallpaper panel to a mounting surface of a component with an adhesive or glue; and attaching the wallpaper to an area where the wallpaper panel is not attached.

[0010] A fifth feature of the present disclosure is a method for installing wallpaper panels, comprising the steps of acquiring identification information assigned to wallpaper, acquiring a wallpaper panel associated with the identification information, attaching the wallpaper to a specified portion, and attaching the acquired wallpaper panel to a mounting surface of a component with an adhesive or glue in a portion other than the specified portion.

[0011] A sixth feature of the present disclosure is a method for installing a wallpaper panel, comprising the steps of acquiring identification information assigned to the wallpaper of the wallpaper panel, acquiring wallpaper associated with the identification information, attaching the wallpaper panel to a mounting surface of a component with an adhesive or glue, and attaching the acquired wallpaper to an area where the wallpaper panel is not attached.

[0012] A seventh feature of the present disclosure is a method for installing a wallpaper panel, comprising the steps of acquiring identification information assigned to the wallpaper of the wallpaper panel, acquiring wallpaper associated with the identification information, attaching the acquired wallpaper to a specified portion, and attaching the wallpaper panel to a mounting surface of a member with an adhesive or glue in a portion other than the specified portion.

[0013] An eighth feature of the present disclosure is summarized as comprising the steps of attaching a wallpaper panel to a mounting surface of a component with an adhesive or glue, acquiring identification information assigned to the wallpaper of the wallpaper panel, acquiring wallpaper associated with the identification information, and attaching the acquired wallpaper to an area where the wallpaper panel is not attached.

[0014] According to the present disclosure, it is possible to provide a wallpaper panel manufacturing method, a wallpaper panel, and a wallpaper panel installation method that do not require the work of pasting wallpaper onto gypsum board at the installation site.

[0015] Furthermore, the present disclosure can provide a method for manufacturing a wallpaper panel that is easy to install without relying on the skill of a craftsman, a wallpaper panel, and an installation method for the wallpaper panel.

[0016] Furthermore, according to the present disclosure, it is possible to provide a wallpaper panel manufacturing method, a wallpaper panel, and a wallpaper panel installation method that can shorten installation time.

[0017] Fig. 1 is a diagram showing an example of the overall configuration of a wallpaper panel 1 according to one embodiment. Fig. 2 is an example of a cross-sectional view of the wallpaper panel 1 according to one embodiment. Fig. 3 is an example of a cross-sectional view of the wallpaper panel 1 according to a first modified example.

[0018] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In the following description of the drawings, identical or similar parts are designated by identical or similar reference numerals. However, it should be noted that the drawings are schematic, and the dimensional ratios and the like may differ from those of the actual parts. Therefore, specific dimensions and the like should be determined with reference to the following description. Furthermore, parts in the drawings may have different dimensional relationships and ratios. In this specification and the drawings, elements having substantially the same functions and configurations are designated by the same reference numerals to avoid redundant description, and elements not directly related to the present invention are not shown.

[0019] (First embodiment) Referring now to Figures 1 and 2, an example of the overall configuration of a wallpaper panel 1 according to a first embodiment of the present invention is shown, and Figure 2 is an example of a cross-sectional view of the wallpaper panel 1 according to this embodiment.

[0020] As shown in FIGS. 1 and 2 , a wallpaper panel 1 according to this embodiment includes wallpaper 10 and a base material 20 .

[0021] 1 and 2, the base material 20 has a front surface 20F, a back surface 20B, an upper surface 20U, a lower surface 20D, a left side surface 20L, and a right side surface 20R. Here, the front surface 20F, the back surface 20B, the upper surface 20U, the lower surface 20D, the left side surface 20L, and the right side surface 20R are determined by the orientation of the base material 20 to be fixed to a member. The front surface 20F and the back surface 20B are the pair of surfaces with the largest areas among the six surfaces.

[0022] In the following, in this embodiment, a stud and a beam are used as an example of the above-mentioned members, but the present invention is also applicable to cases where members other than a stud and a beam are used as such members. In this specification, a stud refers to a member that extends vertically, and a beam refers to a member that extends horizontally.

[0023] Generally, the base material 20 has a substantially rectangular parallelepiped shape. For example, the base material 20 may have a square edge.

[0024] In addition, a part or all of the surface of the base material 20 may be chamfered. Examples of such chamfering include C-chamfering, R-chamfering, and light chamfering (deburring). For example, the base material 20 may have a beveled edge or a tapered edge.

[0025] For example, the base material 20 may be a non-flammable gypsum board made by covering the front and back surfaces of a gypsum core with gypsum board base paper, a resin board, a wooden board such as a veneer made from wood of various trees, plywood, laminated wood, particle board, or fiberboard, a cement-based material such as concrete or mortar, a fiber-reinforced gypsum board, an inorganic non-metallic board made from calcium silicate, or a metal board made from iron, aluminum, or the like, or may be a recycled material (for example, a gypsum board made from recycled materials).

[0026] From the viewpoint of non-combustibility, the base material 20 is preferably an inorganic non-metallic plate such as gypsum board or calcium silicate, a cement-based material such as mortar, or a metal plate. Among these, gypsum board or inorganic non-metallic plate such as calcium silicate is more preferable because it is easy to mass-produce and therefore low cost. If it is desired to attach a magnet to a wall surface, gypsum board with iron powder attached to the surface or gypsum board with a metal plate attached to the surface can be used. Furthermore, from the viewpoint of environmental conservation and effective use of resources, the environmental load can be reduced by using a base material made from recycled materials. Furthermore, the pulp content of such gypsum board base paper is 70 to 170 g / m. ２ is in the range.

[0027] The wallpaper 10 may be paper-based, fiber-based, vinyl chloride resin-based, plastic-based, or inorganic-based. The backing material may be plain paper, flame-retardant paper, inorganic paper, woven fabric, nonwoven fabric, or the like.

[0028] Here, paper-based wallpaper is wallpaper whose main material is paper (plain paper, flame-retardant paper, or paper cloth).

[0029] Fiber wallpaper is wallpaper whose main material is organic fiber. Specifically, fiber wallpaper may be wallpaper whose main material is plant fiber or cellulose-based regenerated fiber such as rayon (including blends or interweavings with chemical fibers), wallpaper whose main material is chemical fiber (acrylic, polyester, etc.), or wallpaper whose main material is animal fiber fabric.

[0030] In addition, vinyl chloride resin wallpaper is made mainly of vinyl chloride resin, or has a surface decorative layer of 20 g / m ２ The above wallpapers use vinyl chloride resin.

[0031] In addition, plastic wallpapers are made primarily of plastics other than vinyl chloride resin, or have a surface decorative layer of 20 g / m ２ The above wallpapers use plastic.

[0032] Furthermore, inorganic wallpaper is wallpaper whose main material is inorganic substances such as inorganic paper, inorganic aggregate, and glass fiber.

[0033] The wallpaper 10 may also include a backing layer that is attached to the base material 20, a synthetic resin layer made of a thermoplastic resin or a thermosetting resin that is laminated onto the backing layer, and a functional layer that is laminated on the surface of the synthetic resin layer.

[0034] In the wallpaper panel 1 according to this embodiment, the wallpaper 10 is folded and attached to the base material 20 with an adhesive 30 containing starch.

[0035] For example, as shown in FIG. 2, the wallpaper 10 may be folded and attached to the base material 20 with a starch-containing adhesive 30 so as to cover the front surface 20F, the left side surface 20L, and the right side surface 20R of the base material 20.

[0036] The inventor discovered a problem in that when wallpaper panel 1, in which wallpaper 10 is attached to base material 20 so as to cover only front surface 20F of base material 20, is attached to studs and beams, wallpaper 10 easily peels off gypsum board 20. Therefore, the inventor succeeded in solving this problem by adopting the configuration described above.

[0037] The inventors also discovered a problem in that when wallpaper panel 1, in which wallpaper 10 is attached to base material 20 so as to cover only front surface 20F of base material 20, is attached to studs and beams, pieces of base material 20 tend to fall off from left side surface 20L and right side surface 20R. Therefore, by adopting the above-described configuration, the inventors succeeded in solving this problem.

[0038] Furthermore, the inventors discovered a problem in that when multiple wallpaper panels 1, each with wallpaper 10 attached to a base material 20 so as to cover only the front surface 20F of the base material 20, are lined up side by side and attached to studs and beams, the sides of the base materials 20 come into contact with each other, creating gaps at the contact surfaces. Therefore, the inventors succeeded in solving this problem by adopting the configuration described above.

[0039] As shown in FIG. 2, in the wallpaper panel 1 according to this embodiment, the wallpaper 10 does not have to cover the upper surface 20U, the lower surface 20D, and the back surface 20B of the base material 20.

[0040] In addition, the wallpaper 10 may be attached to the base material 20 so as to cover the front 20F, left side 20L and right side 20R of the base material 20, and to cover part or all of the top surface 20U, bottom surface 20D and back surface 20B of the base material 20.

[0041] The mass of the adhesive 30 used here is 60 g / m2 in solids. ３ (organic mass is 60g ± 6 / m ３ It is preferable that the temperature is 100°C or less.

[0042] In such a case, the adhesive 30 may be a starch-based adhesive. The mass of the starch-based adhesive is 60 g±6 / m2 in terms of solid content. ３ (organic mass is 60g ± 6 / m ３ Preferably, the starch-based adhesive has a composition (mass%) of 80±2 or more starch paste and 20±2 or less reinforcing agent. The reinforcing agent is either an ethylene vinyl acetate resin emulsion or a vinyl acetate resin emulsion, or a combination thereof. Note that the starch-based adhesive does not necessarily have to contain a reinforcing agent.

[0043] The adhesive 30 may be a combination of the starch-based adhesive and a sealer made of synthetic resin. The mass of the sealer is 10 g±1 / m2 in terms of solid content. ３ (organic mass is 10g ± 1 / m ３ The synthetic resin is preferably an acrylic resin emulsion (acrylic acid ester copolymer emulsion, methacrylic acid ester copolymer emulsion), an ethylene vinyl acetate resin emulsion, or a vinyl acetate resin emulsion, or a combination thereof.

[0044] Alternatively, the mass of the adhesive 30 used here is 40 g ± 4 / m in solids. ３ (organic mass is 40g ± 4 / m ３ It is preferable that the temperature is 100°C or less.

[0045] In this case, the adhesive 30 may be a methylcellulose adhesive. Note that a methylcellulose adhesive is effective when paper is used as the backing layer, and is particularly effective when a nonwoven fabric is used as the backing layer. The mass of the methylcellulose adhesive is 40 g±4 / m2 in solids. ３ (organic mass is 40g ± 4 / m ３ Preferably, the methylcellulose adhesive has a composition (mass%) of 80±2 or more methylcellulose and 20±2 or less reinforcing agent. The reinforcing agent is either an ethylene vinyl acetate resin emulsion or a vinyl acetate resin emulsion, or a combination thereof. Note that the methylcellulose adhesive does not necessarily need to contain a reinforcing agent.

[0046] The adhesive 30 may be a combination of the methyl cellulose adhesive and a sealer made of synthetic resin. The mass of the sealer is 10 g±1 / m2 in terms of solid content. ３ (organic mass is 10g ± 1 / m ３ The synthetic resin is preferably an acrylic resin emulsion (acrylic acid ester copolymer emulsion, methacrylic acid ester copolymer emulsion, etc.), an ethylene vinyl acetate resin emulsion, or a vinyl acetate resin emulsion, or a combination thereof.

[0047] The wallpaper panel 1 having the above-described configuration can be attached to steel studs and beams using the method described in Patent Document 1. Patent Document 1 also discloses a method for attaching gypsum board to steel studs and beams.

[0048] Specifically, first, a pressure sensitive adhesive or glue is applied to the mounting surfaces of the studs and beams (Step C).

[0049] The adhesive may be an acrylic adhesive, a rubber adhesive, a urethane adhesive, a silicone adhesive, or the like, and may be used alone or in combination of two or more. The adhesive may also include adhesive tape.

[0050] The adhesive may be a urea adhesive, a vinyl acetate resin adhesive, a urea resin adhesive, a melamine resin adhesive, a phenolic resin adhesive, an isocyanate adhesive, or the like, and may be used alone or in combination of two or more. The adhesive may also include adhesive tape.

[0051] Second, a part of the back surface 20B of the base material 20 of the wallpaper panel 1 is temporarily fixed to the adhesive or glue (step D).

[0052] Third, a magnetic attraction jig is brought into contact with the front surface 20F of the base material 20 of the wallpaper panel 1 and moved along the adhesive or adhesive, thereby attracting the studs and beams with the magnetic attraction force of the magnetic attraction jig and compressing the wallpaper panel 1 (step E). Permanent magnets such as alnico magnets, ferrite magnets, and neodymium magnets can be used as the magnetic attraction jig. However, instead of a permanent magnet, a temporary magnet such as an electromagnet may also be used as the magnetic attraction jig.

[0053] The wallpaper panel 1 according to this embodiment can be attached to studs and beams using the above-described method because the back surface 20B of the base material 20 is not covered with wallpaper 10. If the back surface 20B of the base material 20 is covered with wallpaper 10, the wallpaper 10 attached to the back surface 20B would prevent the magnetic attraction force of the magnetic attraction jig from attracting the studs and beams and crimping the wallpaper panel 1, and therefore the above-described method could not be used.

[0054] Furthermore, in the wallpaper panel 1 according to this embodiment, if the back surface 20B of the base material 20 is not covered with wallpaper 10, unevenness is less likely to occur at the contact surfaces of the studs and beams, making it easier to apply.

[0055] The area of ​​the front surface 20F and the rear surface 20B is preferably within a range of 100 mm x 100 mm to 1300 mm x 3100 mm.

[0056] This configuration allows for not only common rectangular shapes but also special shapes. For example, this configuration allows for wallpaper panel 1 to be shaped not only when the location where wallpaper panel 1 is to be attached has a common shape, but also when the location where wallpaper panel 1 is to be attached has a special shape (edge, etc.). Furthermore, this configuration allows for easy transportation of wallpaper panel 1 from the factory to the installation site.

[0057] The thickness of the wallpaper 10 attached to the front surface 20F, left side surface 20L, and right side surface 20R may be uniform. This configuration allows the wallpaper panel 1 to be finished without any unevenness. This configuration also allows the wallpaper panel 1 to be securely fixed by studs and beams.

[0058] Furthermore, the result of the wet strength test of the wallpaper 10 as specified in JIS A 6921 may be 5 N / 1.5 cm or more.

[0059] Furthermore, the wallpaper 10 may be attached to the base material 20 by lamination. Specifically, the wallpaper 10 may be attached to the front surface 20F of the base material 20 using a laminating machine. In such a case, the wallpaper 10 is folded and rolled up so as to be attached so as to cover the left side surface 20L and the right side surface 20R of the base material 20. The wallpaper 10 may be cut so as not to cover the top surface 20U and the bottom surface 20D of the base material 20. For example, the edges of the wallpaper 10 may be cut, and the portions covering the back surface 20B, top surface 20U, bottom surface 20D, etc. of the base material 20 may or may not be cut depending on the length of the wallpaper.

[0060] According to this configuration, the wallpaper can be cut to fit the size of the wallpaper panel, so that the amount of cut wallpaper that is discarded is reduced, and wallpaper panels can be produced efficiently.

[0061] The wallpaper panel 1 may be used on a ceiling. In such a case, the wallpaper panel 1 may be attached to cover five surfaces of the base material 20 (specifically, the front surface 20F, the left side surface 20L, the right side surface 20R, the top surface 20U, and the bottom surface 20D).

[0062] When the wallpaper panel 1 is used on a ceiling, pieces of the base material 20 are likely to fall off not only from the left side 20L and right side 20R of the base material 20 but also from the top surface 20U and bottom surface 20D of the base material 20.

[0063] Therefore, as described above, by attaching the wallpaper 1 to cover the five surfaces of the base material 20, even when the wallpaper panel 1 is used on a ceiling, it is possible to prevent fragments of the base material 20 from spilling off the wallpaper panel 1 at the contact surface of adjacent wallpaper panels 1 and to prevent gaps from forming at the contact surface of adjacent wallpaper panels 1.

[0064] According to the wallpaper panel 1 of this embodiment, it is possible to avoid the work of attaching the wallpaper 10 to the base material 20 at the installation site, thereby shortening the installation time.

[0065] Alternatively, the wallpaper panels 1 may be attached to the studs and beams with an adhesive or glue at a factory, and then transported to the site with the wallpaper panels 1 attached to the studs and beams. Multiple wallpaper panels 1 may be attached to the studs and beams, in which case a unit construction method or two-by-four construction method can be used on site, resulting in a significant reduction in construction work, a shorter construction period, and improved work efficiency.

[0066] At the construction site, there may be areas where the wallpaper panel 1 cannot be applied, and wallpaper must be applied to those areas. In such cases, the craftsman has to go to the construction site and search for wallpaper with the same pattern as the wallpaper 10 of the wallpaper panel 1. Furthermore, if the same pattern of wallpaper is not available at the construction site, it is necessary to procure it there.

[0067] Therefore, the above-mentioned trouble can be eliminated by using identification information to identify wallpaper with the same pattern as the wallpaper 10 attached to the wallpaper panel 1. Furthermore, using such identification information, the wallpaper 10 on the wallpaper panel 1 can be freely selected. Here, such identification information is composed of symbols, numbers, letters, etc.

[0068] Such identification information is provided not only to the wallpaper panel 1 (wallpaper 10 or base material 20) but also to wallpaper having the same pattern as the wallpaper 10. For example, in the wallpaper panel 1, such identification information may be provided to the front or back surface of the wallpaper 10, or the front surface 20F or back surface 20B of the base material 20, etc.

[0069] In addition, such identification information may be displayed as numbers, symbols, letters, etc. so that workers at the construction site can visually confirm the identification information, or may be attached to wallpaper with the same pattern as wallpaper panel 1 or wallpaper 10 in the form of a multidimensional barcode or QR code (registered trademark).

[0070] Here, such identification information may be written on the packaging material or product label of the wallpaper panel 1, or may be written on the base member 20.

[0071] Furthermore, such identification information may be a number different from the identification information of the wallpaper panel 1. In such a case, it is preferable to explain the relationship between the two in a pamphlet, construction specifications, installation specifications, interior finish schedule, installation instructions, etc.

[0072] The following describes an example of a method for installing the wallpaper panel 1. Note that the wallpaper panel 1 used in the following installation method is not limited to the wallpaper panel 1 according to this embodiment, and any wallpaper panel can be used.

[0073] Furthermore, in the following installation method, the wallpaper panel 1 can also be used on a ceiling. In this case, similar to when the wallpaper panel 1 is used on a wall, installation can be simplified and the work time (especially the time required to work on a stepladder) can be shortened, thereby reducing the risk of injury.

[0074] In the first example, first, the user (representing one of the client, the coordinator, and the worker) obtains the identification information assigned to the wallpaper desired by the client.

[0075] Here, the client is the person who requests the wallpaper panel 1, and the worker is the person who works at the construction site. The coordinator is the person who listens to the client's requests, gives advice on the interior design of the building, and coordinates the space comprehensively. For example, the coordinator may be a corporation such as a house manufacturer, builder, construction company, or renovation company, or an individual such as a designer.

[0076] For example, the user may obtain such identification information by scanning it with a mobile communication terminal, etc. Alternatively, the user may obtain such identification information from a website, a sample book, a pamphlet, a construction specification, a working specification, an interior finish schedule, or a working procedure.

[0077] Second, the user acquires the wallpaper panel 1 associated with the acquired identification information. For example, the user acquires the wallpaper panel 1 by transmitting the acquired identification information to a distributor of the wallpaper panel 1 via a communication network. Here, the distributor of the wallpaper panel 1 may create the wallpaper panel 1 using the wallpaper associated with the identification information notified by the user. Note that such means of transmission may include telephone, facsimile, etc.

[0078] Third, a user (e.g., a worker) attaches the wallpaper panel 1 to the mounting surfaces of the studs and beams with an adhesive or glue.

[0079] Fourth, a user (e.g., a worker) applies the above-mentioned wallpaper to the portions where no wallpaper panel 1 is applied. At this time, when applying the above-mentioned wallpaper to the portions where no wallpaper panel 1 is applied, the user (e.g., a worker) may apply a base material such as gypsum board (including resin panels, wood boards, metal boards, concrete boards, various cement boards, calcium silicate boards, and hydrated inorganic material-containing boards) to the mounting surfaces of the studs and beams, and then apply the wallpaper to the base material.

[0080] It should be noted that the user (for example, a worker) may apply the above-described wallpaper to an area where the wallpaper panel 1 cannot be applied.

[0081] In this example, the user (for example, a worker) may attach the wallpaper panel 1 after attaching the above-mentioned wallpaper.

[0082] In the second example, first, the user obtains the identification information assigned to the wallpaper 10 of the wallpaper panel 1 .

[0083] Second, the user obtains the wallpaper associated with the obtained identification information.

[0084] Third, a user (e.g., a worker) attaches the wallpaper panel 1 to the mounting surfaces of the studs and beams with an adhesive or glue.

[0085] Fourth, the user (for example, a worker) pastes the obtained wallpaper onto the portion where the wallpaper panel 1 is not pasted.

[0086] In this example, the user (for example, a worker) may attach the wallpaper panel 1 after attaching the above-mentioned wallpaper.

[0087] In the third example, first, a user (e.g., a worker) attaches the wallpaper panel 1 to the mounting surface of the studs and beams with an adhesive or glue.

[0088] Second, a user (for example, a worker) obtains the identification information assigned to the wallpaper 10 of the wallpaper panel 1 .

[0089] Third, the user obtains the wallpaper associated with the obtained identification information.

[0090] Fourth, the user (for example, a worker) pastes the obtained wallpaper onto the area where the wallpaper panel 1 is not pasted.

[0091] The third example assumes a case where, during installation of wallpaper panel 1, it is discovered that wallpaper with the same pattern as wallpaper 10 is required, or a case where wallpaper needs to be repaired.

[0092] (Modification 1) Modification 1 will be described with reference to FIG. 3, focusing on differences from the first embodiment.

[0093] In this first modified example, as shown in Fig. 3, the wallpaper 10 is attached to the base material 20 with an adhesive 30 so as to cover the front surface 20F. Here, the adhesive 30 may be a starch-containing adhesive, a methylcellulose-based adhesive, or any other adhesive. For example, the wallpaper 10 may be attached to the base material 20 by lamination.

[0094] An example of a method for manufacturing the wallpaper panel 1 according to the first modified example will be described below.

[0095] First, adhesive 30 is automatically applied to wallpaper 10 or base material 20 by an application mechanism (step A).

[0096] A starch-containing adhesive or a methylcellulose-based adhesive may be used as the adhesive 30. With this configuration, unlike the case where a hot melt adhesive is used, there is no need to heat the adhesive, and therefore the time required for the application process can be reduced.

[0097] It should be noted that a step of cutting the wallpaper 10 to an appropriate size using a slitter or the like may be performed before or after the above-described step A. This allows the wallpaper to be cut to fit the size of the wallpaper panel, which reduces the amount of cut wallpaper that is discarded and allows for efficient production of wallpaper panels.

[0098] Furthermore, when the backing material of the wallpaper 10 is a nonwoven fabric or the like, a pressure sensitive adhesive may be used instead of the adhesive 30 .

[0099] Second, the wallpaper 10 is pressure-bonded to the front surface 20F of the base material 20 by a pressure-bonding mechanism (step B). For example, the wallpaper 10 is pressure-bonded to the front surface 20F of the base material 20 by applying pressure or pressing.

[0100] For example, the above-described coating step and pressure-bonding step may be performed in a series using a machine equipped with a coating mechanism and a pressure-bonding mechanism. The coating mechanism and the pressure-bonding mechanism may be provided in the same machine or in separate machines.

[0101] Furthermore, when the adhesive 30 is applied to the wallpaper 10, it is not necessary to provide a step of causing the adhesive 30 to penetrate the wallpaper 10 between the above-mentioned step A and the above-mentioned step B.

[0102] Conventionally, after the adhesive 30 is applied to the wallpaper 10, a process called "open time" (for example, 30 minutes, 60 minutes, etc.) is provided to allow the adhesive 30 to penetrate the wallpaper 10. Note that this open time can be affected by temperature and humidity.

[0103] In contrast to this, according to the present modified example 1, the wallpaper 10 is evenly pressed by the pressing mechanism, so there is no need to provide a step (open time) for allowing the adhesive 30 to penetrate the wallpaper 10 .

[0104] For example, in a machine having a coating mechanism and a pressing mechanism, temporarily stopping wallpaper 10 on the conveying line from the coating mechanism to the pressing mechanism does not constitute a process of penetrating adhesive 30 into wallpaper 10.

[0105] According to this modified example 1, the wallpaper 10 is attached to the base material 20 using a machine equipped with an application mechanism and a pressing mechanism, so compared to when the wallpaper 10 is attached to the base material 20 manually or when the wallpaper 10 is attached to the base material 20 on-site, the wallpaper panel 10 can be manufactured more efficiently and manpower can be reduced.

[0106] In addition, in this modified example 1, an example is shown in which wallpaper 10 is attached to base material 20 so as to cover the front surface 20F, but the present invention is not limited to such an example, and wallpaper 10 may be attached so as to cover three surfaces of base material 20 (specifically, front surface 20F, left surface 20L, and right surface 20R, or front surface 20F, top surface 20U, and bottom surface 20D), or may be attached so as to cover five surfaces of base material 20 (specifically, front surface 20F, left surface 20L, right surface 20R, top surface 20U, and bottom surface 20D).

[0107] (Modification 2) Hereinafter, a method for installing the wallpaper panel 1 according to Modification 2 will be described, focusing on the differences from the first embodiment described above.

[0108] First, a pressure sensitive adhesive or adhesive is applied to a member to which the wallpaper panel 1 is attached (step C). Such members include columnar members and wall-shaped members.

[0109] The columnar member includes the studs and beams described above, and may be, for example, a metal frame or a non-metal frame such as a wooden shaft.

[0110] Wall-like components include gypsum board, mortar, metal plate, plywood, concrete plate, brick plate, roof tile, ceramic tile, fiber-reinforced cement plate, glass fiber-mixed cement plate with a thickness of 3 mm or more, fiber-mixed calcium silicate plate with a thickness of 5 mm or more, steel plate, aluminum plate, plaster plate, stone plate, rock wool plate, glass wool plate, etc.

[0111] Second, a part of the back surface 20B of the base material 20 of the wallpaper panel 1 is temporarily fixed to the above-mentioned adhesive or adhesive (step D).

[0112] Third, the wallpaper panel 1 is pressure-bonded (step E). For example, a robot (e.g., an arm-type robot) may be used to pressure-bond the wallpaper panel 1. Here, the robot may use a magnet to pressure-bond the wallpaper panel 1.

[0113] Such a robot may be used to carry the wallpaper panel 1. In such a case, the wallpaper panel 1 may be loaded onto the robot itself.

[0114] Furthermore, a robot may be used to inspect the wallpaper panel 1 (check for stains, etc.), or the robot may be used to cut the wallpaper panel 1 to a desired size.

[0115] A robot may be used to apply the adhesive or the adhesive to the above-mentioned member. For example, the robot may be used to apply the adhesive with a roller or a brush, or to spray the adhesive. The robot may also be used to perform at least one of the steps of gripping the adhesive tape, cutting the adhesive tape, peeling off the release paper from the adhesive tape, and attaching the adhesive tape to the above-mentioned member.

[0116] A robot may also be used to attach the wallpaper panel 1 to the above-mentioned adhesive or glue. For example, a robot may be used to perform at least one of the steps of grasping the wallpaper panel 1, positioning the wallpaper panel 1, and arranging the wallpaper panel 1. Note that various sensors may be used in the step of positioning the wallpaper panel 1.

[0117] Furthermore, a robot may be used to check the finished product, or the wallpaper panel 1 attached to a member may be attached and pressed in a predetermined location.

[0118] Although the present invention has been described in detail using the above-described embodiments, it is clear to those skilled in the art that the present invention is not limited to the embodiments described herein. The present invention can be implemented in modified and altered forms without departing from the spirit and scope of the present invention as defined by the claims. Therefore, the description in this specification is intended to be illustrative and explanatory and does not have any limiting meaning on the present invention.

[0119] 1... Wallpaper panel 10... Wallpaper 20... Base material 20F... Front 20B... Back 20U... Top 20D... Bottom 20R... Right side 20L... Left side 30... Adhesive

Claims

1. A method for manufacturing a wallpaper panel including a base material having a front surface, a back surface, an upper surface, a lower surface, a left side surface, and a right side surface and wallpaper, the method comprising: Step A of applying an adhesive to the wallpaper or the base material by an application mechanism; and Step B of pressing the wallpaper onto the front surface of the base material by a pressing mechanism, wherein the wallpaper has a lining material, and any one of ordinary paper, flame-retardant paper, inorganic paper, woven fabric, and non-woven fabric is used for the lining material. A method for manufacturing a wallpaper panel.

2. A method for installing a wallpaper panel manufactured by the method for manufacturing a wallpaper panel according to claim 1, the method comprising: Step C of applying an adhesive or an adhesive to a member for attaching the wallpaper panel; Step D of temporarily fixing a part of the back surface of the base material of the wallpaper panel to the adhesive or the adhesive; and Step E of pressing the wallpaper panel. A method for installing a wallpaper panel.

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