JP2016164357A - Manufacturing method of fitting panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a fitting panel capable of improving productivity, by sticking a required face bar without using an adhesive, by realizing restraint of warping of the face bar and a crosspiece as a fitting by making the most use of merits when using a metal material as a frame body.SOLUTION: A manufacturing method includes a first process of oppositely arranging a pair of face bars 5a and 5b so as to generate a cavity 8 between mutual ones in the depth direction of a recessed part 9 in a plane part enclosed by first crosspieces and second crosspieces of a metal plate, by arranging the first crosspieces 3a and 3b of the metal plate in the longer direction of the recessed part of a metal mold 10 having the recessed part in the plane part corresponding to an external shape of a frame body 2, and arranging the second crosspieces 4a and 4b in the shorter direction of the recessed part of the metal mold, and a second process of integrating the first crosspieces, the second crosspieces, the face bars, and a foam resin body 6 of the metal plate by injecting, foaming, and hardening a foam resin composition in the cavity by foam resin injection ports 7a and 7b provided in the second crosspieces while holding the face bars so that respective surfaces of the first crosspieces, the second crosspieces, and the face bars of the metal plate become flush after the first process.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a joinery panel.

  2. Description of the Related Art Conventionally, interior panels having a structure in which plate-like face materials are attached to the front and back surfaces of a frame body assembled from wooden crosspieces are widely known as fittings such as hinged doors and sliding doors. And what uses LVL (single board laminated material, Laminated Veneer Lumber) for a crosspiece, and uses MDF (medium density fiberboard, Medium Density Fiberboard) for a surface material is known.

  However, in the case of the interior panel using the above-mentioned wood material, since the environment such as temperature difference and humidity difference is different between the room side and the hallway side, warping due to the difference in drying and moisture absorption may occur. .

  In order to suppress such warpage, in a structure in which a decorative plywood is attached to both sides of a wooden frame body, a synthetic resin foam is filled in the space between the decorative plywoods to prevent warping due to a temperature difference or the like. Has been proposed (see, for example, Patent Document 1).

  In this structure, a synthetic resin having self-adhesive properties of closed cells is injected into a gap between both decorative plywoods from a hole formed in the upper horizontal rail. By filling the voids with the synthetic resin foam in this way, the foam, the frame body and the decorative plywood are integrated to prevent warping.

  However, in the door structure described in Patent Document 1, it is difficult to suppress the occurrence of warpage and distortion because a long wooden material is used for the frame.

  On the other hand, a structure using a metal material with little warpage even if it is a long material has been proposed (for example, see Patent Documents 2 and 3).

  In the door panel described in Patent Document 2, boards are attached to both surfaces of a metal frame, and a synthetic resin foam stock solution is mixed and injected into a hollow portion to be foamed and cured.

  Moreover, in the metal door described in Patent Document 3, the frame is assembled by locking the locking pieces at the ends of the metal vertical bars to the locked pieces provided at both ends of the horizontal bars. Face materials are fitted on the front and back surfaces of the portion surrounded by the frame body, and the foamed synthetic resin is injected into the hollow portion from the injection port provided in the horizontal rail, and is foamed and cured.

Japanese Unexamined Patent Publication No. 7-18893 Japanese Patent Laid-Open No. 50-161565 JP-A-8-4435

  However, in the door panel described in Patent Document 2, it is necessary to prepare a panel-like hollow structure by pasting boards with adhesives on both sides of a metal frame in advance, and it is easy to stick with the required strength. Therefore, it was not possible to easily manufacture a door panel having sticking strength.

  In addition, the metal door manufacturing method described in Patent Document 3 needs to bend metal plates to produce vertical bars and horizontal bars, so that metal bars can be easily manufactured. In addition, there is a problem that it is difficult to reduce the manufacturing cost due to the large number of parts.

  The present invention has been made in view of the circumstances as described above, and realizes the suppression of warp by taking advantage of the advantage of using a metal material for a frame, and further, without using an adhesive, the required face material. An object of the present invention is to provide a method for manufacturing a joinery panel that can be attached and can improve productivity.

  In order to solve the above-described problems, a method for manufacturing a joinery panel according to the present invention includes a frame having a rectangular outer shape, wherein the frame extends in a longitudinal direction and is disposed at a pair of edges of the frame. The first crosspiece of the metal plate, a second extending in the short direction of the frame, disposed on the other pair of edges of the frame, and provided with a foamed resin injection port at the center of at least one of them A pair of plate-like face materials having the same shape as the plane in the frame surrounded by the frame body, and a gap formed between the pair of plate-like face materials. A method for manufacturing a joinery panel in which a foamed resin body is disposed, wherein the first crosspiece of the metal plate is arranged in a longitudinal direction of the concave portion of a mold having a concave portion in a planar portion corresponding to the outer shape of the frame body. And the second crosspiece is arranged in the short direction of the recess of the mold, and the first crosspiece and the second crosspiece of the metal plate A first step of opposingly arranging a pair of face members so as to generate a gap between the recesses in the depth direction of the recessed portion, and after the first step, the first crosspiece of the metal plate A foamed resin composition is formed in the gap from a foamed resin injection port provided in the second bar material while holding the face material so that the surfaces of the second bar material and the face material are flush with each other. And a second step of integrating the first crosspiece, the second crosspiece, the face material, and the foamed resin body of the metal plate by injecting, foaming, and curing an object.

  According to the method for manufacturing a panel for joinery of the present invention, the advantage of using a metal material for a frame body is utilized to suppress warpage, and the required face material can be adhered without using an adhesive. The productivity when manufacturing a panel for joinery can be improved.

(A) is the schematic plan view which showed one Embodiment of the panel for joinery obtained by the manufacturing method of the panel for joinery of this invention, (b) is A-A 'sectional drawing of (a). It is B-B 'sectional drawing of Fig.1 (a). (A) is the schematic cross-sectional view which has arrange | positioned the 1st crosspiece of a metal plate, the 2nd crosspiece, and a face material in the recessed part of the metal mold | die and metal mold | die in one Embodiment of the manufacturing method of the panel for joinery of this invention. It is. (B) is C-C 'sectional drawing of (a). It is the schematic sectional drawing which illustrated the face material in the panel for joinery of the present invention. It is the perspective view which notched and showed a part of upper surface material 5a of the panel structure before inject | pouring the foaming resin composition in the 2nd process of the manufacturing method of the panel for joinery of this invention. In one Embodiment of the panel for joinery of this invention, it is a schematic sectional drawing at the time of arrange | positioning a spacer between two facing face materials.

  Fig.1 (a) is the schematic plan view which showed one Embodiment of the panel for joinery obtained by the manufacturing method of the panel for joinery of this invention, (b) is AA 'sectional drawing of (a). is there. FIG. 2 is a cross-sectional view taken along the line B-B ′ of FIG.

  As shown to Fig.1 (a), (b), the panel 1 for joinery is provided with the frame 2 whose external shape is a rectangular shape. The frame body 2 extends in the longitudinal direction, extends in the short direction of the frame body 2 and the first crosspieces 3a and 3b of the metal plate disposed at the pair of edges of the frame body 2, It has 2nd crosspieces 4a and 4b which are arrange | positioned at a pair of edge and were provided with the foaming resin injection inlets 7a and 7b in the center of at least one.

  The joinery panel 1 includes a pair of plate-like face members 5a and 5b having the same shape as the plane inside the frame surrounded by the frame body 2, and a foamed resin is formed in the gap 8 formed therebetween. A body 6 is disposed. The first crosspieces 3a and 3b, the second crosspieces 4a and 4b, and the face pieces 5a and 5b of the metal plate are injected by injecting a foamed resin composition forming the foamed resin body 6 from the foamed resin injection ports 7a and 7b. By being cured, it is integrated with the foamed resin body 6.

  As shown in FIG. 1B and FIG. 2, the face members 5 a and 5 b are arranged on an in-frame plane surrounded by the frame body 2 so that the surface of the joinery panel 1 is flush with the thickness T. Has been.

  FIG. 3 (a) is a view showing a first crosspiece 3a, 3b, a second crosspiece 4a, 4b and a surface of a metal plate in a mold and a recess of the mold in an embodiment of the manufacturing method of a joinery panel according to the present invention. It is a schematic cross-sectional view which has arrange | positioned material 5a, 5b. (B) is C-C 'sectional drawing of (a).

  In the manufacturing of the joinery panel 1 described above, first, as a first step, a mold 10 having a recess 9 in a planar portion corresponding to the outer shape of the frame body 2 is used as shown in FIGS. 3 (a) and 3 (b). . The first crosspieces 3a and 3b of the metal plate are arranged in the longitudinal direction of the concave portion 9 of the mold 10, and the second crosspieces 4a and 4b are arranged in the short direction of the concave portion 9 of the mold 10. In addition, one of the pair of face members 5a and 5b is placed on the bottom of the recess 9 in a plane portion surrounded by the first crosspieces 3a and 3b and the second crosspieces 4a and 4b of the metal plate. The other one of the pair of face members 5a and 5b is arranged to face each other so as to generate the gap 8.

  Next, as a second step, while holding the face materials 5a and 5b so that the surfaces of the first crosspieces 3a and 3b, the second crosspieces 4a and 4b and the face materials 5a and 5b of the metal plate are flush with each other. The foamed resin composition is injected into the gap 8 from the foamed resin injection ports 7a and 7b provided in the second crosspieces 4a and 4b, and foamed and cured. Thereby, the 1st crosspieces 3a and 3b of metal plates, the 2nd crosspieces 4a and 4b, the face materials 5a and 5b, and the foamed resin body 6 which the said foamed resin composition expanded and hardened are integrated.

The first step and the second step will be described in detail below.
(1) First Step In the first step, as described above, the mold 10 having the recess 9 is used, and the first crosspieces 3a and 3b of the metal plate and the recess 9 of the mold 10 are arranged in the longitudinal direction of the recess 9. The second crosspieces 4a and 4b are arranged in the short direction.

  In the present embodiment, as shown in FIGS. 3A and 3B, a plurality of magnets 11 are embedded in the recess 9 of the mold 10, and the first crosspieces 3 a and 3 b that are metal plates are attached. Magnetic force can be held in the recess 9 of the mold 10. The embedding position of the magnet 11 is not particularly limited as long as the first crosspieces 3a and 3b can be held. In particular, it is preferably embedded in the standing surface 12 of the recess 9 of the mold 10. In addition, the magnet 11 is partially in the longitudinal direction of the recess 9 as long as it can hold the first crosspieces 3a and 3b of the metal plate disposed on the standing surface 12 in the longitudinal direction of the recess 9 of the mold 10. What is necessary is just to embed, and it is not necessary to embed to the whole standing surface 12 of the recessed part 9 of the metal mold | die 10. FIG.

  Although there is no restriction | limiting in particular about the material of the metal plate used as 1st crosspiece 3a, 3b, The steel plate etc. which are magnetic metals are illustrated preferably. Moreover, as the 1st crosspiece 3a, 3b, the stainless steel etc. with which generation | occurrence | production of rust etc. was suppressed are illustrated preferably.

  Since said 1st crosspiece 3a, 3b is a metal plate, the rigidity of the frame 2 will improve more.

  At this time, it is considered that the thickness direction of the 1st crosspiece 3a, 3b of a metal plate corresponds with the width direction of the panel 1 for joinery. In this case, since the contact area between the first crosspieces 3a and 3b and the magnet 11 embedded in the standing surface 12 of the concave portion 9 of the mold 10 is maximized, magnetic force retention is ensured.

  In the first crosspieces 3a and 3b, it is preferable that the outer surface portion of the frame body 2 is decorated. By applying makeup to the first crosspieces 3a and 3b in advance, the process of applying makeup to the outer surface portion of the assembled joinery panel 1 can be omitted, and the manufacturing method of the joinery panel 1 as a whole is simplified. Can be

  When applying makeup to the first crosspieces 3a, 3b, methods such as applying a makeup print or attaching a resin film can be applied.

  As shown in FIG. 3 (b), when the second crosspieces 4 a and 4 b are arranged in the concave portion 9 of the mold 10, the longitudinal direction of the concave portion 9 is provided at the central portion of the second crosspiece 4 a and 4 b. The foamed resin injection ports 7a and 7b are provided on at least one side in the same direction. The foamed resin composition can be injected from the foamed resin injection ports 7a and 7b, and the foamed resin composition and the air in the gap 8 can be discharged from the other one of the foamed resin injection ports 7a and 7b. For this reason, excessive pressure is not applied to the frame 2 and the face materials 5a and 5b from the inside of the gap 8 in the outward direction, and warpage and deformation of the obtained joinery panel 1 are suppressed in advance. . The foamed resin composition may be injected into either of the foamed resin injection ports 7a and 7b. Alternatively, the foamed resin injection port 7a may be formed only in one of the second crosspieces 4a, and an air discharge hole may be provided separately.

  The second crosspieces 4a and 4b are not particularly limited as long as they are materials with little warpage. For example, a wood material, a metal material, a resin material, etc. are illustrated. If it is a wood material, weight reduction of the frame 2 will be attained, and it will become effective for weight reduction of the panel 1 for joinery by extension. Moreover, if it is a wood material, formation of the foamed resin injection inlets 7a and 7b is easy. Solid wood, LVL, or PB (Particle Board) can be used as the wood material, and a material that does not cause a relative deviation in dimensions due to the environment such as temperature and humidity is preferably applied. The

  In addition, in the space 8, as long as the foamed resin composition to be injected in the second step does not hinder the space 8 from being filled without any gaps, the strength of the frame 2 is improved and the storage space for embedding the handle base is embedded. An intermediate crosspiece (not shown) can be disposed in the gap 8 for the purpose of partitioning and forming.

  In this case, the intermediate rail member is installed in a direction parallel to the first rail members 3a and 3b so that both ends in the longitudinal direction of the intermediate rail member are in contact with the opposing second rail members 4a and 4b. In addition, the intermediate crosspiece is installed in a direction parallel to the second crosspieces 4a and 4b, and both ends of the intermediate crosspiece in the length direction are in contact with the first crosspieces 3a and 3b. May be. When the intermediate crosspiece is arranged in a direction parallel to the second crosspieces 4a and 4b, the intermediate crosspiece needs to be provided with a through hole or a notch through which the foamed resin composition can pass.

  Further, in the first step, one of the face materials 5a and 5b is placed on the bottom of the recess 9, and the other one is disposed so as to face the gap 8 in the depth direction.

  FIG. 4 is a schematic cross-sectional view illustrating a face material in the joinery panel of the present invention. Examples of the face materials 5a and 5b include those in which a makeup moisture-proof sheet 14 and the like are attached to the surface of the base material 13 via an adhesive 15 as shown in FIG. As for the base material 13, particle board, MDF, high density fiber board and the like are preferably exemplified from the viewpoint of handling property and workability.

  The makeup moisture-proof sheet 14 is not particularly limited as long as it is a makeup moisture-proof sheet usually used for a decorative board or the like. Examples thereof include a vinyl chloride resin sheet, a polyethylene resin sheet, a polypropylene resin sheet, a polycarbonate resin sheet, an acrylic resin sheet, and a urethane resin sheet.

Moreover, as the adhesive 15 used when sticking the cosmetic moisture-proof sheet 14 on the surface of the base material 13, a water-insoluble adhesive that hardly transfers moisture to the wooden base material 13 is preferably exemplified. Examples of water-insoluble adhesives include, for example, solution-type acrylic copolymers, synthetic rubber adhesives, and hot-melt adhesives that are thermoplastic synthetic resins, alone or in combination of two or more. be able to. Moreover, the thing which used the epoxy resin type, urethane type, vinyl chloride type, vinyl acetate type adhesives etc. individually or in combination of 2 or more types can be illustrated. Further, for example, the cosmetic moisture-proof sheet 14 and the base material 13 are integrated with the base material 13 by closely contacting the heat-shrinkable cosmetic moisture-proof sheet 14 and the wooden base material 13 without using the adhesive 15. It can also be converted.
(2) Second Step FIG. 5 is a perspective view in which a part of the upper face member 5a of the panel structure before injecting the foamed resin composition in the second step of the method for manufacturing a joinery panel according to the present invention is cut away. FIG.

  In the second step, after the first step, the first crosspieces so that the surfaces of the first crosspieces 3a and 3b, the second crosspieces 4a and 4b, and the face pieces 5a and 5b of the metal plate are flush with each other. While holding 3a, 3b, second crosspieces 4a, 4b, and face members 5a, 5b, as shown in FIG. 5, from the foamed resin injection port 7a provided in the second crosspiece 4a, into the gap 8 A foamed resin composition is injected. The injected foamed resin composition is foamed and hardened in the gap 8 so that the first crosspieces 3a and 3b, the second crosspieces 4a and 4b, the face members 5a and 5b, and the foamed resin composition are metal plates. The foamed and cured foamed resin body 6 is integrated.

  In the second step, the foamed resin that is the main component of the foamed resin composition to be injected into the gap 8 is not particularly limited as long as it is a foamed resin having self-adhesive properties of closed cells capable of injection foam molding. For example, a polyurethane resin, an epoxy resin, a phenol resin, or the like may be used alone or in combination of two or more.

  A foaming agent, a curing agent, a flame retardant, and the like can be added to the foamed resin composition as long as the foamed resin composition is not hindered.

  By injecting such a foamed resin composition into the gap 8 and foaming and curing, the foamed resin composition spreads uniformly to the corners of the gap 8 without any gaps as shown in FIG. The crosspieces 3a and 3b, the second crosspieces 4a and 4b, and the face members 5a and 5b can be integrated. In the manufacturing method of the panel 1 for joinery, it is not necessary to bond the first crosspieces 3a and 3b, the second crosspieces 4a and 4b, and the face pieces 5a and 5b, respectively, and the manufacturing process is simplified as a whole. can do. Moreover, the required integrated strength can be obtained.

  The foamed resin injection ports 7 a and 7 b are plugged by a part of the foamed resin body 6 after foaming and curing the foamed resin composition. In such foamed resin injection ports 7a and 7b, a part of the foamed resin body 6 may be left exposed, or the second crosspieces 4a and 4b may cover the foamed resin injection ports 7a and 7b. You may apply makeup to the outer surface part of the frame 2 of this.

  Since the foamed resin body 6 in which the foamed resin composition is cured is excellent in heat insulation and waterproof properties, when the panel 1 for joinery is used as a joinery, the temperature difference or humidity between the room side and the hallway side Generation | occurrence | production of the curvature by a difference or the generation | occurrence | production of the curvature by the humidity difference in the panel 1 for joinery can be suppressed.

  FIG. 6 is a schematic cross-sectional view in the case where a spacer is disposed between two facing face materials in one embodiment of the joinery panel of the present invention.

  In the first step and the second step, as shown in FIG. 6, a spacer 16 can be disposed in advance in the gap 8 to support one of the face materials 5 a and 5 b. That is, by placing at least one spacer 16 between the two facing face materials 5a and 5b, the face material 5a arranged on the upper side in the depth direction of the recess 9 is supported from the back side, Deflection of the face material 5a can be suppressed, and the surface of the joinery panel 1 can be finished flat.

  The material of the spacer 16 is not particularly limited as long as warpage of the joinery panel 1 can be suppressed. As the spacer 16, a foamed resin body 6 obtained by curing the foamed resin composition can be used. Thereby, since it becomes difficult to generate a temperature difference and a humidity difference in the gap, it is possible to suppress warping. Further, when the injected foamed resin composition is cured, the spacer 16 is also integrated, and the fixture panel 1 is less likely to be biased in strength and performance.

  Moreover, using the apparatus provided with the suction mechanism as the press plate in the second step, the first crosspieces 3a, 3b and second of the metal plate are sucked while sucking the face material 5a disposed on the upper side in the depth direction of the recess 9. The face materials 5a and 5b can be held so that the surfaces of the crosspieces 4a and 4b and the face materials 5a5b are flush with each other. In addition, a suction mechanism that sucks the first crosspieces 3a and 3b may be provided to hold the first crosspieces 3a and 3b.

  The joinery panel 1 having the structure as described above realizes suppression of warpage and is easy to manufacture. And joinery, such as a hinged door and a sliding door, is formed by having the joinery panel 1 as a base material. For example, a joinery is formed by attaching a handle to the surface of the face material 5.

  Although an Example is shown below, the manufacturing method of the panel for joinery is not limited to an Example.

  Two steel plates with decorative printing of 2000 mm in length as the first cross member are respectively arranged on the longitudinal edges of the recesses of the mold, and two PBs with a length of 800 mm are used as the second cross members. Was placed on the edge of the recess of the mold in the short direction. Since the magnet was partially buried in the standing surface in the longitudinal direction of the concave portion of the mold, the steel plate was held in a vertical state. In the frame surrounded by the first crosspiece and the second crosspiece, two MDFs each having a moisture-proof surface-bonded sheet adhered as a face material were disposed. At this time, a foamed resin body in which the same foamed resin composition as that injected into the gap was cured was partially disposed as a spacer between the two facing face materials. In this manner, a void surrounded by the first crosspiece, the second crosspiece, and the face material was formed in the concave portion of the mold.

  Thereafter, while holding the first crosspiece, the second crosspiece, and the face material, polyurethane resin was injected into the gap from one foamed resin injection port of the second crosspiece. Excess polyurethane resin was discharged from the foamed resin injection port of the other second cross member facing the other. After the polyurethane resin was foamed and cured, the press was depressurized, and the joinery panel in which the first crosspiece, the second crosspiece, the face material, and the polyurethane resin foam were integrated was taken out from the mold.

DESCRIPTION OF SYMBOLS 1 Panel for fittings 2 Frame 3a, 3b 1st crosspiece 4a, 4b 2nd crosspiece 5a, 5b Face material 6 Foamed resin body 7a, 7b Foamed resin injection port 8 Air gap 9 Recessed part 10 Mold

Claims (4)

In the frame whose outer shape is rectangular,
The frame body extends in the longitudinal direction and extends in the short direction of the frame body and the first pair of metal plates disposed at a pair of edges of the frame body, and the other pair of ends of the frame body A second crosspiece disposed on the edge and provided with a foamed resin injection port at the center of at least one;
A pair of plate-like face materials having the same shape as the plane inside the frame surrounded by the frame body, and a foamed resin body is disposed in a gap formed between the pair of plate-like face materials A method for manufacturing a panel for joinery,
The first crosspiece of the metal plate is arranged in the longitudinal direction of the concave portion of the mold having a concave portion in a planar portion corresponding to the outer shape of the frame body, and the second crosspiece is arranged in the short direction of the concave portion of the mold. A pair of face materials are arranged opposite to each other so that a gap is generated between the metal plates in the depth direction of the concave portion in a planar portion surrounded by the first and second crosspieces of the metal plate. 1 process,
After the first step, the first crosspiece of the metal plate, the second crosspiece, and the facepiece are provided on the second crosspiece while holding the facepiece so that the surfaces thereof are flush with each other. The foamed resin composition is injected into the gap from the foamed resin injection port, and the first and second crosspieces, the face piece and the foamed resin body of the metal plate are integrated by foaming and curing. The manufacturing method of the panel for joinery characterized by including the 2nd process to do.   The manufacturing method of the panel for joinery according to claim 1, wherein makeup is applied to an outer surface portion of the frame body in the first crosspiece of the metal plate.   The plurality of magnets are embedded in the mold, and the magnets hold the first crosspiece of the metal plate in the concave portion of the mold. Method of manufacturing joinery panels.   The manufacturing method of the panel for joinery as described in any one of Claim 1 to 3 which arrange | positions a spacer in the said space | gap beforehand and supports the said face material in the said 1st process.

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