JP2001164845A - Fitting and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fitting such as a door being lightweight and having a sense of luxury. SOLUTION: A fiber plate 31 having an average density of 0.13 to 0.18 g/cm3 and given good moldability and lightness as a core 3 is provided with an irregular pattern 31B on its front face and/or its back face, and surface plates 5 provided with irregular patterns 5B corresponding to the irregular pattern 31B on the front face and/or back face of the core 3 are applied to the front and back of the core 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fitting such as a door and a method of manufacturing the fitting.

[0002]

BACKGROUND OF THE INVENTION It is desirable that such fittings be lightweight. An example of a lightweight fitting is a flash door. The flash door has a front panel attached to the front and back surfaces of a frame-shaped core material, and is lightened by a hollow structure. However, since the flash door is hollow, it is light in weight, but does not have a feeling of filling and has a poor sense of quality. Therefore, a flash door is provided in which a synthetic resin foam such as a polyurethane foam or a polystyrene foam is filled. Although the above flash door is certainly lightweight and has a feeling of filling, it has a problem of environmental pollution when processing wastes because it is filled with a synthetic resin foam.

[0003]

2. Description of the Related Art There has been provided a flush door in which a fiberboard made of wood fiber is filled (Japanese Patent Laid-Open No. 9-1997).
No. 317339). The fiberboard has decay properties, does not generate toxic gas even when incinerated, can be defibrated to be regenerated into fibers, and can treat waste without polluting the environment.

[0004]

As shown in FIG. 7, the surface of the flash door (11) has a frame (15A), a decorative edge (15B),
A head plate (15C) and the like are provided, and the decorative edge (15B) has a deep drawing uneven pattern. However, the core material which is the above fiberboard
(13) has a density of 0.2 to 0.5 g / cm ³ , and it is difficult to form such a deep drawing uneven pattern by molding. Therefore, the deep drawing uneven pattern (15B ), And the fiberboard to be filled inside is the front and back layers (13A, 13B) and the middle layer (1
3C), and the decorative edges of the front and back layers (13A, 13B)
Only part (15B) is removed to make it hollow. Because of this, the deep drawing uneven portion (15B) of the surface plate (15) is not backed up by the front and back layers (13A, 13B) of the fiberboard, and there is a problem that the impact resistance is reduced at this portion.

[0005]

The present invention SUMMARY OF] as a means for solving the conventional problems described above, the core material (3) as an average density of 0.13~0.18g / cm ³ of weight fiberboard (31) The lightweight fiberboard (31) is formed into a molded fiberboard (31) provided with a concavo-convex pattern (31B) on the front and / or back side thereof, and the core material (3)
A surface plate provided with an uneven pattern (5B) corresponding to the uneven pattern (31B) on the front and / or back surface of the core material (3) on the front and back surfaces
It provides a fitting (1) with (5). The lightweight fiberboard (31) has an average density of 0.10 to 0.14 g / cm ³ at a thickness portion of 20% of the total thickness from the surface, and has an average density of 0% at a thickness portion of 20% of the total thickness from the back surface. .15-
0.19 g / cm ³ , and the density gradually increases from the front surface to the back surface, and the average density of the whole is 0.1 g / cm ³ .
The weight is preferably 13 to 0.18 g / cm ³ , and the lightweight fiberboard (31) contains 90% or more of fibers having a length of 4 mm or more, and has a freeness of 10 to 15 defibrator seconds (D). .
Desirably, it is made of wood pulp having a roughness of S.). Further, the core material (3) is composed of two molded fiberboards (31).
Preferably, the core material (3) is a molded fiberboard (31) formed by molding the lightweight fiberboard (31).
However, it is desirable that two sheets are superimposed on each other with the mutual high-density side inside. Further, the fitting (1) is a door, and the frame (5A, 31) is provided on the core (3) and the surface plate (5).
A), the decorative edge portions (5B, 31B), and the end plate portions (5C, 31C) are desirably integrally formed. Furthermore, in the present invention, the average density is 0.1.
13-0.18 g / cm ³ lightweight fiberboard (31) is molded and provided with an uneven pattern (31B) on the front and / or back to form a core material
(3) and the surface plate (5) provided with an uneven pattern (5B) corresponding to the uneven pattern (31B) of the core material (3) on the front and / or back surface of the core material (3). The lightweight fiberboard (31) is desirably produced by a wet method, and the surface plate (5) is desirably produced by a dry method.

[0006]

[Function] A lightweight fiberboard (3) used as a core material (3) in the present invention.
Since (1) has an average density of 0.13 to 0.18 g / cm ^3, it is lightweight and easily forms a deep drawn concavo-convex pattern (31B) on the front and / or back surface by molding. Therefore, it is not necessary to remove the core material (3) at the portion of the deep drawing uneven pattern (5B) of the surface plate (5) to make it hollow. In this way the surface plate
Since the deep drawing uneven pattern (5B) of (5) is also backed up by the core material (3), the impact resistance of this portion does not decrease.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention is shown in FIGS. As shown in FIGS. 2 and 3, a door (1) shown in FIG. 1 includes a frame material (2) and a core material inserted in the frame material (2).
Surface plates (5, 5) are adhered to the front and back surfaces of the frame core (4) composed of (3), and the peripheral surface is covered with a rim tape (6).
The front panel (5, 5) on the front and back of the door (1) has a frame (5A) and a decorative edge.
(5B), a head plate (5C) is formed.

The core material (3) is formed by two sheets as shown in FIG.
It is a polymer obtained by laminating fiber boards (31, 31).
The plate (31, 31) has a thickness of 20% of the total thickness from the surface.
Average density of 0.10 to 0.14 g / cm^ThreeAnd the back side
The average density of the thickness of 20% of the total thickness is 0.15 to
0.19g / cm^ThreeAnd going from the front surface to the back surface
Therefore, the density is increasing gradually, and the average density of the whole is 0.1.
13-0.18g / cm ^ThreeOf lightweight fiberboard (31)
You.

The lightweight fiber board (31) is mainly a board made of a cellulosic natural fiber such as wood pulp, cotton fiber, hemp fiber, bamboo fiber, pear fiber, etc., but polyester is used in place of the natural fiber or together with the natural fiber. Synthetic fibers such as fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, and acetate fibers can also be used. Desirable fibers are mainly fibers having a length of 2 to 32 mm containing 90% or more of fibers having a length of 4 mm or more and a freeness of 10%.
Wood pulp having a roughness of ~ 15 defibrator seconds (DS). If the fiber length is less than 2 mm, the density of the lightweight fiberboard (31) becomes too high,
If it exceeds 2 mm, the fibers are likely to be entangled in a thread form and the dispersibility in the slurry becomes poor. The freeness is 15D. S. If the density exceeds 10, the density of the lightweight fiberboard (31) becomes too high.
D. S. If it is less than 1, the density of the lightweight fiberboard (31) becomes too low, the entanglement between the fibers becomes insufficient, and the strength tends to be insufficient.

In the lightweight fiberboard (31), a binder is used to bind the fibers. Examples of the binder include glue, gelatin, casein, starch, modified starch, oxidized starch, dextrin, gum arabic, sodium alginate, polyvinyl alcohol, carboxymethylcellulose, methylcellulose, hydroxyethylcellulose, sodium polyacrylate, sodium polymethacrylate, and polyacrylamide. , Polymethacrylamide, polyvinyl methyl ether, vinyl acetate-maleic acid copolymer, styrene-maleic acid copolymer, polyvinylpyrrolidone, partially saponified polyacrylate,
A water-soluble resin such as a partially saponified polymethacrylate or a paste is used. Instead of the water-soluble resin or together with the water-soluble resin or the paste, a thermosetting resin such as a melamine resin, a urea resin, and a phenol resin is used. Resin, polyethylene,
Polypropylene, ethylene-propylene copolymer, ethylene-propylene terpolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester, heat Thermoplastic synthetic resin such as thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, urethane resin prepolymer, epoxy resin prepolymer, melamine resin prepolymer Polymer, urea resin prepolymer, phenol resin prepolymer, diallyl phthalate prepolymer, acrylic oligomer, polyvalent isocyanate, methacrylic ester monomer, diallyl phthalate monomer, etc. Prepolymers, oligomers, synthetic resin precursor such as monomers may be used. The binder is provided in the form of powder, liquid, solution, or emulsion.

In addition to the above-mentioned raw materials, in the lightweight fiberboard (31), water repellents such as paraffin, wax, silicone oil, higher fatty acid zirconium salt, chlorinated paraffin, ethylene tetrabromide, tricresyl phosphate, antimony oxide And the like may be added.

A preferable method for producing the lightweight fiberboard (31) is a wet method. In the wet method, the raw material is dispersed in water to prepare a slurry. In this case, the binder is added in an amount of about 3 to 10% by weight based on the fibers. If the amount of the binder is less than 3% by weight, the binding power of the fibers becomes small and the fibers are easily loosened, and the strength becomes insufficient. On the other hand, if the content exceeds 10% by weight, the lightweight fiberboard (31) becomes hard and the cushioning property decreases, and the density of the lightweight fiberboard (31) may increase due to the cohesive action of the binder. Other raw materials, such as a water repellent and a flame retardant, are usually added in an amount of several percent by weight or less. The above raw materials are dispersed in water to prepare a slurry.
To obtain (31), the concentration of solids in the slurry was 0.5
It is desirable to adjust it to 2.0% by weight.

The above-mentioned slurry is formed into a paper sheet to form a mat. As a paper-making machine used for paper-making, it is desirable to use a long-mesh paper-making machine having excellent drainage. The supply amount of the slurry is about 300 to 500 kg / m ² .

As described above, the supply amount of the slurry having a low solid content is increased, and the thickness of the mat immediately after the supply of the slurry is set to 25 to
In order to make the paper relatively thick as 70 mm, a long net type paper machine having good drainage is used. By using such a fourdrinier-type papermaking machine, while forming the mat by suction-dewatering the slurry supplied on the fourdrinier, the solid content concentration in the slurry becomes lower and higher in the downward direction. Due to the solid concentration gradient, the density of the formed mat is increased downward and increased downward.

The mat thus formed is further usually pressed by a roll press, adjusted to a thickness of 18 to 50 mm, and has a smooth surface and an average density of 0.13 to 0.15 mm.
This gives a lightweight fiberboard (31) of 0.18 g / cm ³ . The lightweight fiberboard (31) is further press-formed to form a frame on the surface on the low density side.
(31A), decorative edge (31B), end plate (31C)
(31). The lightweight fiberboard (31) has a surface having a total thickness of 20 mm.
% Of the average density of the thickness portion is 0.10 to 0.14 g / cm ³
However, the deep drawing unevenness pattern (31B) can be formed very easily because of the low density. The size of the concave / convex pattern (31B) is set so that the concave / convex pattern (5B) of the surface plate (5) just fits.

The thickness of the molded fiberboard (31) is finally 1
0-30mm, natural drying or 100-150 ° C
In molding fiberboard average density of the whole it is dried by heating and drying of about 2-5 hours 0.26~0.36g / cm ^{3 (3}
1).

It is desirable that the lightweight fiberboard (31) of the present invention is manufactured by the above-mentioned wet method, in which a low-density fiberboard can be easily obtained.
It may be manufactured by a dry method. In the dry method, a mixture of the above raw materials is sprayed on a template to form a mat. In this case, the raw material mixture is separated into a plurality of sections according to the roughness of the fibers to be used, and the raw material mixture separated into the plurality of sections in the order of roughness is sprayed. In this case, the section of the maximum roughness may be the lowermost layer, or conversely, the uppermost layer. The mat formed in this way is usually hot-pressed to bind fibers with a binder, to smooth the surface and to adjust the thickness, and to provide a frame (31) on the surface.
A), a decorative edge portion (31B), and a mirror plate portion (31C) are formed.

In the case of the dry method, a powdery binder is mainly used. In the case of using a water-soluble resin or paste, water is added to the raw material mixture, or steam is added by hot pressing. The water-soluble resin or paste is activated by blowing. However, a binder in the form of a solution, an emulsion or the like may be used.

In such a lightweight fiberboard (31), the low-density surface side provides lightness and good moldability, and the high-density surface side provides high mechanical strength and compression resistance.
As a result, a lightweight core material (3) having both good moldability and high mechanical strength can be obtained. However, the average density of 20% of the total thickness from the lower density surface is 0.10.
If it is less than g / cm ³ , the surface strength will be weak, and problems such as fluffing will occur. If it exceeds 0.14 g / cm ³ , good moldability will not be obtained. Further, the average density of the portion having a thickness of 20% of the total thickness from the surface having the higher density is 0.15 g / cm ^3.
If less than 0.1%, the mechanical strength of the core material becomes insufficient,
If it exceeds 9 g / cm ³ , it becomes difficult to obtain a lightweight core material (3).

The surface plate (5) is desirably formed by a dry method in which a thin plate can be easily obtained and a deep drawing uneven pattern (5B) can be easily formed. In the dry method, as described above, a mixture of the above raw materials is sprayed on a template having a predetermined uneven pattern on a mold surface to form a mat, and usually hot pressed. The density of the surface plate (5) is 0.7 to 1.2.
g / cm ³ , and the thickness is 3-4 mm.

As mentioned above, the formed fiberboard (31) is superposed on two sheets to form a core material (3). In this case, the formed fiberboard (31) has the high-density side inside, that is, Lay them so that the back sides are in contact with each other. The core material (3) is fitted into the frame material (2) as described above to form a frame core body (4), and the front and rear surfaces of the frame core body (4) are the front plates (5, 5) as described above. ) Is attached by an adhesive.

The door (1) is made of a lightweight fiberboard (31) as a core material (3), so that it is light in weight, easy to carry and install, and has a complete interior. Therefore, it has good mechanical strength such as impact resistance, and has a feeling of filling and gives a high-grade feeling.

FIGS. 4 and 5 show another embodiment of the present invention. In this embodiment, the end plate (5C) of the door (1) of the previous embodiment
The glass plate (5D) is fitted through the molding material (5E).

FIG. 6 shows still another embodiment of the present invention. The present embodiment relates to the folding door (1B), in which the core material is formed of a single formed fiberboard (31), and therefore, the uneven pattern (5B) is formed on only one surface, and the uneven pattern (5B) is formed on the other surface. ) Is not formed, and the other surface plate (51) is flat.

[0025]

According to the present invention, since it is lightweight and completely solid, it has a feeling of filling even in the uneven pattern portion, and it is possible to obtain a fitting having a high commercial value giving an extremely high quality feeling.

[Brief description of the drawings]

 1 to 3 show one embodiment of the present invention.

FIG. 1 is a perspective view

FIG. 2 is an exploded perspective view.

FIG. 3 is a cross-sectional view taken along line AA in FIG. 1. FIGS. 4 and 5 show another embodiment.

FIG. 4 is a perspective view

FIG. 5 is a sectional view taken along line BB in FIG. 4;

FIG. 6 is a sectional view corresponding to AA in FIG. 1 of still another embodiment.

FIG. 7 is a sectional view corresponding to AA in FIG. 1 of a conventional example.

[Explanation of symbols]

 1 Fittings (doors) 3 Core material 5 Surface plate (surface material) 5A Frame 5B Rough pattern (decorative edge) 5C End plate 31 Molded fiberboard (lightweight fiberboard) 31A Frame 31B Rough pattern (decorative edge) 31C End plate

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E016 HA10 KA05 LA10 LA16 LB05 LB13 LC03 MA01 MA11 NA07 PA02 QA13 2E162 AA09 AA10 BA06 BA10 CC08 4F100 AJ04 AK01 AP03 AT00A AT00B AT00C AT00D BA04 BA06 BA10A BA10B BA43B BA01C DG01B DG01C DG02B DG02C DG03 EH41 EJ19 EJ20 GB07 GB81 HB21 HB21A HB21B HB21C HB21D JA05B JA05C JA13B JA13C JK01 JK10 JL02 JL03 YY00B YY00C

Claims (8)

[Claims] An average density of the core material is 0.13 to 0.18.
g / cm ³ of a lightweight fiberboard is used to form a lightweight fiberboard having an uneven pattern on the surface and / or the back of the lightweight fiberboard. A fitting having a surface plate provided with an uneven pattern corresponding to the uneven pattern on the back side. 2. The lightweight fiberboard has a total thickness of 20 mm from the surface.
% Of the average density of the thickness portion is 0.10 to 0.14 g / cm ³
The average density of a portion of 20% of the total thickness from the back surface is 0.15 to 0.19 g / cm ³ , and the density gradually increases from the front surface to the back surface. claim density of 0.13~0.18g / cm ³ 1
Fittings described in 3. The lightweight fiberboard comprises 9 fibers having a length of 4 mm or more.
The fitting according to claim 1 or 2, comprising wood pulp containing 0% or more and having a roughness of 10 to 15 defibrator seconds (DS). 4. The fitting according to claim 1, wherein said core material is made of a polymer obtained by laminating two molded fiberboards. 5. The fitting according to claim 4, wherein the core material is a molded fiberboard formed by molding the lightweight fiberboard according to claim 2, and two pieces of the fiberboard are overlapped with the high density side inside. 6. A door according to claim 1, wherein said core member and said surface plate are integrally formed with a frame portion, a decorative edge portion and a mirror plate portion.
Fittings as described in ~ 5 7. A light-weight fiberboard having an average density of 0.13 to 0.18 g / cm ³ is formed into a core by providing an uneven pattern on the surface and / or back to form a core, and the front and / or back of the core are provided. A method of manufacturing a fitting, comprising: attaching the surface plate provided with an uneven pattern corresponding to the uneven pattern of the core material to the surface material. 8. The lightweight fiberboard is manufactured by a wet method,
The method for manufacturing a fitting according to claim 7, wherein the face plate is manufactured by a dry method.