JP2537752B2 - Building door integrally molded with plastic - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building door in which the entire door or almost the entire door is integrally molded of plastic.

[0002]

BACKGROUND OF THE INVENTION Doors for buildings are composite materials. That is, it is manufactured by combining a surface plate, a strength plate, a crosspiece, a filler, a molding, and the like. For this reason, it takes time to manufacture, and it is difficult to mass-produce inexpensively. Molding the main part of the door out of plastic eliminates this drawback. Small molded products have been developed as doors that realize this. For example, Japanese Patent Application Laid-Open No. 59-202376 describes that as a manufacturing technique of a refrigerator, the surface is blow-molded with plastic and the inside is filled with a heat insulating material to reduce the number of assembly steps. The method described in this publication is
It can be applied to the manufacture of architectural doors.

[0003]

However, it is difficult to manufacture doors for large buildings by this method. This is because it is difficult to give the blow-molded surface material sufficient strength. Doors for buildings are ordinary and have a width of about 80 cm and a height of about 190 cm. It is difficult to blow mold the surface material used for such a large door with plastic to obtain sufficient strength. In order to have strength, the surface material needs to be considerably thick. Thick plastic plates cannot be easily blow molded. In addition, the cost of raw materials for plastics increases, and the door becomes heavy.

Furthermore, it is difficult for a door whose surface is blow-molded with a plastic plate to have sufficient strength at a portion for fixing a door lock or a hinge. In particular, the hinge fixing part connects a large and heavy door to the frame, so that a strong force is applied to the mounting part. When the hinge is fixed to the blow-molded thin surface plate, the fixed portion is deformed and the strength cannot be sufficient. Japanese Patent Laid-Open No. 149672/1993 discloses a technique for easily providing a hinge to obtain sufficient strength. This publication describes a door structure in which a hinge, which is a hinge, is integrated with the door. A part of the hinge of the door described in this publication is thinly formed so that it can be bent.

The door having this structure has a feature that since the hinge portion can be formed when the door is formed, it can be mass-produced at low cost and the hinge portion can be strengthened. However, this structure thins a part of the door to make it a hinge,
Cannot be used for indoor doors. This is because the hinge limits the shape of the door.

The present invention was developed for the purpose of solving these conventional drawbacks. An important object of the present invention is to enable mass production at low cost, to cope with diversification of shapes (designs), to make it lightweight and to increase the strength of the fixed part so that it has the same appearance as a conventional door. The purpose is to provide a door for the building.

[0007]

In order to achieve the above-mentioned object, a building door integrally molded of plastic of the present invention has the following constitution. The door for a building is formed integrally or almost entirely from foamed plastic. A non-foamed layer 1 is provided on the surface of the door, and a foamed layer 2 is provided inside the door. The non-foamed layer 1 and the foamed layer 2 are connected to each other through the fine foamed layer 3, and the fine foamed layer 3 has fine bubbles when approaching the non-foamed layer 1 and approaches the foamed layer 2 side. The bubbles grow larger. Further, a hard fixing member 4 is inserted inside the foamed plastic to form a non-foaming layer 1 in a portion that is in close contact with the surface of the fixing member 4. The non-foaming layer 1 that adheres to the surface of the fixing member 4 is connected to the non-foaming layer 1 on the surface of the door in order to firmly hold the fixing member 4. A non-foamed layer 1 that adheres to the surface of the fixing member 4,
The inner foam layer 2 is also connected through the fine foam layer 3 in which the bubbles become fine when approaching the non-foam layer 1 and the bubbles become large when approaching the foam layer 2 side.

[0008]

In the door for a building of the present invention, the surface is the non-foaming layer 1, the inside is the foaming layer 2, and at the boundary between the non-foaming layer 1 and the foaming layer 2, fine bubbles are formed on the non-foaming layer side. Large bubbles are formed on the foam layer side. In this way, the door molded so that the bubbles increase from the non-foaming layer 1 toward the foaming layer 2 inside can make the whole non-foaming layer 1 light in weight. This is because the expansion ratio inside can be increased to make the surface tough. Especially, the impact strength of the surface important for the door can be remarkably improved. This is because the non-foamed layer 1 is supported by the fine bubble layer and the fine bubble layer is supported by the foamed layer 2 having large bubbles.

Further, the non-foamed layer 1 is brought into close contact with the surface of the fixing member 4 inserted inside the door. This non-foaming layer 1 is connected to the non-foaming layer 1 on the door surface to reinforce it. The non-foaming layer 1 on the surface of the fixing member 4 which is connected to the non-foaming layer 1 on the door surface is not only supported by fine bubbles to have sufficient strength, but also connected to the non-foaming layer 1 on the door surface. Be reinforced. When the door is opened and closed, the fixed member 4 is impacted. The fine bubble layer and the foam layer 2 at the boundary of the non-foam layer 1 serve as a buffer layer that absorbs the impact of the door, and can reduce the impact of the door due to the impact. Actually, when you open and close the door, you can close it quietly without making a loud noise.

[0010]

Embodiments of the present invention will be described below with reference to the drawings. However, the following embodiments are examples of doors for buildings for embodying the technical idea of the present invention, and the present invention does not specify the structure of doors for buildings to the following.

Further, in this specification, in order to make it easy to understand the claims, the numbers corresponding to the members shown in the embodiments are referred to as "claims", "actions", and "actions". In the column of "Means for solving the problem". However, the members shown in the claims are
It is by no means specific to the members of the examples.

The building door integrally formed of plastic shown in the front view of FIG. 1 and the sectional views of FIGS. 2 and 3 is integrally formed of plastic. The plastic with which the door is integrally molded is a hard modified urethane foam.
Modified urethane foam doors are ideal as interior doors because they are flame-retardant. Further, since the hard modified urethane foam can be foam-molded by mixing two liquids, it is not necessary to use a large injection molding machine and can be manufactured by an inexpensive molding machine. In addition, the modified urethane foam door has the feature that it can be molded using an inexpensive mold. This is important for door manufacturing. This is because the door requires a large formwork because it produces various designs in various kinds in small quantities. However, the door of the present invention does not specify the modified urethane as the plastic material used for integral molding. For example, a foam such as a polyvinyl chloride resin, a polystyrene resin, an acrylic resin, an epoxy resin, a silicone resin or a phenol resin can be used.

The door shown in FIGS. 1 to 3 is formed with a rectangular frame along the outer periphery on both sides. The end plate is formed with a concave portion inside the frame. Further, the doors shown in these figures have a V-shaped groove 5 formed along the center of the outer peripheral surface. As shown by the chain line in the figure, the groove 5 can be finished neatly by inserting its end when the surface sheet 6 is stretched on the surface of the door.

In a door in which a surface sheet 6 is stretched on the surface of an integrally molded door, the surface design of the door can be changed by changing the stretched surface sheet 6. However, it is not always necessary to stretch the surface sheet 6 on the surface of the integrally molded door. This is because the surface of the non-foamed layer 1 can be cleanly finished when the plastic is foam-molded.
As a method of surface-treating a door at the time of molding, there is a method of temporarily fixing a sheet material to be surface-treated on the surface of a molding die. In this method, plastic is injected into a mold that is clamped, and the pattern of the surface sheet 6 that is temporarily fixed during foam molding is transferred to the surface of the door for a clean surface treatment. Further, the door may be integrally molded and then surface-painted for surface treatment.

FIG. 3 is a vertical sectional view of the door. In the door shown in this sectional view, the bottom groove 7 is formed along the lower edge, and the ridges 8 are provided on both sides of the bottom groove 7. The door of this structure is
It has a feature that the height can be easily adjusted by cutting the ridge 8 at the lower edge. Since the ridge 8 is thin, the height of the door can be adjusted by cutting it more easily than cutting the entire door.

FIG. 4 is an enlarged cross-sectional view of the surface portion of the integrally molded door. As shown in this figure, the door has a non-foamed layer 1 on the surface and a foamed layer 2 inside. Non-foam layer 1
Makes the surface of the door a beautiful smooth surface. The foam layer 2 reduces the weight of the door. The boundary between the non-foaming layer 1 and the foaming layer 2 is formed so that the bubbles become finer when approaching the non-foaming layer 1 and gradually increase when approaching the foaming layer 2 side inside the door. This is to reduce the weight of the entire door and increase the surface strength. The non-foamed layer 1 on the surface of the door can be molded by cooling with a mold for foam-molding plastic. When the mold is forcibly cooled to a low temperature, the film pressure of the non-foamed layer 1 increases. When the non-foamed layer 1 becomes thicker, the portion where fine bubbles are formed becomes thicker and the surface strength of the door becomes stronger. To cool the formwork,
If the mold is a mold, a cooling water passage is provided in the mold, and cooling water is caused to flow there. The temperature of the mold is adjusted to adjust the thickness of the non-foamed layer 1 and the thickness of the layer in which fine bubbles are formed. The door provided with the non-foamed layer 1 on the surface can be made to have a sufficient expansion ratio as a whole to have a sufficient strength as a door, and in particular, the surface strength can be increased.

Further, the integrally molded door is molded by inserting a fixing member 4 for fixing a hinge or a door lock. 5 and 6 are cross-sectional views of a portion where the fixing member 4 for fixing the hinge 9 to the door is inserted. The fixing member 4 shown in these figures is a box-shaped member made by welding metal. The outer width of the fixing member 4 is narrower than the outer width of the door as shown in FIG. 6, so that this does not appear on the surface of the door. The box-shaped fixing member 4 is welded to the fixing plate 4A. The fixing plate 4A is an opening of the fixing member 4 and is located near the side surface of the door. Fixed plate 4A
Is for fixing the hinge 9, and four screw holes for screwing the hinge 9 are provided here. Figure 6 shows the screw holes.
As shown in, a screw for screwing the hinge 9 is screwed in.

Further, the fixing member 4 is, as shown in FIG.
It has an anchor protrusion 4B that projects to the outer periphery inside the door. The anchor protrusion 4B projects into the inside of the foam layer 2 to be inserted, and firmly fixes the fixing member 4 inside the door.

7 and 8 are sectional views of the door in which the fixing member 4 for fixing the door lock 11 is embedded. The door shown in these figures has a box-shaped fixing member 4 embedded by welding a metal plate. The fixing member 4 has an opening bent to both sides and a nut 10 is welded to the back surface of the bent portion 4C. The door lock 11 is connected to the fixing member 4 with a screw that penetrates the bent portion and is screwed into the nut. Fixing member 4 shown in this figure
Also has an anchor protrusion 4B protruding inside the door. This is because the fixing member 4 is firmly fixed inside the door. The fixing member 4 has a deep box shape so that the door lock 11 can be built therein, and is made narrower than the width of the door so as to be embedded inside the door.

As shown in FIG. 9, the non-foamed layer 1 is provided on the outer surfaces of the anchor protrusion 4B and the fixing member 4 so as to be in close contact with them. As shown in FIG. 9, the non-foamed layer 1 is formed in close contact with the entire surface of the fixing member 4. As shown in FIGS. 5 and 6, the non-foaming layer 1 formed on the surface of the fixing member 4 is integrally formed by being connected to the non-foaming layer 1 formed on the surface of the door. In the door that connects the fixing member 4 and the non-foamed layer 1 on the door surface to each other, the embedding strength of the fixing member 4 is significantly improved. This is because the non-foamed layer 1 on the surface of the fixing member 4 can be supported by the non-foamed layer 1 on the surface of the door.

Further, the non-foamed layer 1 on the surface of the fixing member 4 is
The fine foam layer 3 is connected to the foam layer 2. In the fine foam layer 3, the bubbles become smaller when approaching the non-foam layer 1, and the bubbles become larger when approaching the foam layer 2 side. The fixing member 4 and the non-foaming layer 1 on the door surface are connected to each other to form the non-foaming layer 1
In the door in which the fine foam layer 3 and the foam layer 2 are filled in the interior of the door without any gap, the non-foam layer 1 on the surface of the fixing member 4 is supported on the door surface by the non-foam layer 1 and is filled inside. Since the deformation is prevented by the fine foam layer 3 and the fine foam layer 2, the fixing member 4 can be embedded extremely firmly.

[0022]

The building door of the present invention has the following excellent features. High-quality doors can be mass-produced at low cost. This is because the entire door or almost the entire door is integrally molded with plastic. A door integrally molded with plastic can be mass-produced with the same shape by injecting plastic into a mold and performing foam molding. In particular, even if there are complicated patterns on the surface, the manufacturing cost does not increase, and it is possible to mass-produce high-quality doors at low cost. Further, the noteworthy feature of the door of the present invention is that the material used can be reduced and the weight can be reduced, and the hinges, door locks and the like can be firmly fixed. That is, the door of the present invention forms a non-foaming layer that is connected to the embedded fixing member and the door surface, and the inside of the door is a foaming layer, and a non-foaming layer is formed between the foaming layer and the non-foaming layer. This is because the bubbles become smaller as they approach, and the bubbles become larger as they approach the side of the foam layer, forming a fine foam layer. The door of this structure can support the non-foaming layer that adheres to the surface of the fixing member by the non-foaming layer on the door surface, and further, the inside of the non-foaming layer is filled with the fine foam layer without any gap. The layer can prevent deformation of the non-foamed layer, the fixing member can be firmly embedded, and the hinge and the door lock can be reliably fixed. The surface strength of the door can be increased to make it lighter. that is,
This is because the non-foamed layer supported by the foamed layer is formed on the surface of the door through the fine foamed layer. Doors with sufficient surface strength prevent surface damage and become durable and tough doors. In particular, the door of the present invention has the feature that the amount of plastic used can be reduced and the surface strength can be increased.
Therefore, the door of the present invention realizes an ideal feature as a door of the future, which is capable of reducing raw material costs and providing a durable and high-class design. The height of the door can be easily adjusted. This is because the inside of the door is made of a foam layer, so that the door can be easily cut.
The foam layer has a very low density of plastic, and the foamed bubbles can be easily cut into a predetermined size. Although there are a non-foamed layer and a fine foamed layer on the surface, these layers are much thinner than the foamed layer and can be easily cut. Therefore, the door of the present invention in which the fine foam layer and the non-foam layer are formed on the surface of the foam layer has a feature that the height can be easily adjusted by cutting the lower end. In particular, doors that use a foam layer inside do not have internal reinforcements or crosspieces inside the face plate, unlike conventional doors made of composite materials, so there are few restrictions on the cut portion.
It has the feature that the lower end can be cut and adjusted to the optimum height for the site of use.

[Brief description of drawings]

FIG. 1 is a front view of a door according to an embodiment of the present invention.

FIG. 2 is a horizontal sectional view of the door shown in FIG.

FIG. 3 is a vertical sectional view of the door shown in FIG.

FIG. 4 is an enlarged sectional view of the door surface.

FIG. 5 is a vertical sectional view of a portion where a hinge fixing member is embedded inside a door.

FIG. 6 is a horizontal sectional view of a portion where a hinge fixing member is embedded inside the door.

FIG. 7 is a vertical cross-sectional view of a portion where a fixing member for locking a door is embedded inside the door.

FIG. 8 is a horizontal cross-sectional view of a portion where a door lock fixing member is embedded inside the door.

FIG. 9 is an enlarged cross-sectional view of the surface of the fixing member.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Non-foaming layer 2 ... Foaming layer 3 ... Fine foaming layer 4 ... Fixing member 4A ... Fixing plate 4B ... Anchor convex part 4C ...
Bent portion 5 ... Groove 6 ... Surface sheet 7 ... Bottom groove 8 ... Convex strip 9 ... Hinge 10 ... Nut 11 ... Door lock

Claims (1)

(57) [Claims] 1. A door is provided with a non-foaming layer (1) on the surface of the door and a foaming layer (2) on the inside of the door. The foam layer (1) and the foam layer (2) are connected via a fine foam layer (3), and the fine foam layer (3) has small bubbles when approaching the non-foam layer (1). The foaming layer (2) is formed so that the bubbles become large when approaching the foaming layer (2), and furthermore, a rigid fixing member (4) is inserted inside the foamed plastic to adhere to the surface of the fixing member (4). The non-foaming layer (1) is formed on the part, and the non-foaming layer adheres to this fixing member (4).
(1) is connected to the non-foaming layer (1) on the surface with the door,
Even at the boundary between the non-foaming layer (1) that adheres to the surface of the fixing member (4) and the foaming layer (2) inside, the bubbles become smaller when approaching the non-foaming layer (1), and the foaming layer (2) A building door integrally molded with plastic that has a fine foam layer (3) in which air bubbles increase when approaching.