JP5682199B2 - Lightweight door panel and manufacturing method thereof - Google Patents

Description

  The present invention relates to a lightweight door panel and a method for manufacturing the same, and more particularly to a lightweight door panel having a structure in which a periphery is surrounded by a steel plate and a light core material is filled therein and a method for manufacturing the same.

  Conventionally, various lightweight panels with a structure in which a core material such as a paper honeycomb is sandwiched between a first surface plate and a second surface plate made of steel and the surface plates are connected to each other are widely used as door panels and partition panels. Has been.

  For example, Patent Document 1 has a structure in which a core material is sandwiched between a first surface plate and a second surface plate, and a box-shaped reinforcing metal fitting is provided on one upper and lower ends, and at least at the upper and lower ends. It is a door panel device in which a hinge for opening and closing is attached using a reinforcing metal fitting, and the first surface plate and the second surface plate are bent inwardly at a right angle around the decorative plate, and the upper edge plate and the lower surface plate The edge plate and the side edge plates are formed, and the upper edge plate and the lower edge plate of the first surface plate and the upper edge plate and the lower edge plate of the second surface plate are butt-joined to each other, Set so that both side edge plates of the second surface plate are joined in a superposed state on the outside of both side edge plates, place the decorative plate of the first surface plate downward on the bench, Place and position the upper and lower reinforcing metal fittings coated with an adhesive on the end, and then display the decorative plate on the first surface plate. After the core material coated with adhesive is placed on both sides, the second surface plate is placed with the decorative plate facing up, and both side edge plates of the second surface plate are placed outside the side edge plates of the first surface plate. And the downward reinforcement plate of the upper edge plate of the first surface plate and the downward reinforcement plate of the upper edge plate of the second surface plate are butt-joined to each other, and the upward reinforcement plate of the lower edge plate of the first surface plate And the upper reinforcement plate of the lower edge plate of the second surface plate are butted and joined, edge members are arranged on both side surfaces of the first surface plate and the second surface plate, and the tapping screw penetrating the edge member from the side is superposed. The door panel apparatus of the structure attached by screwing in the prepared hole of the said side edge board is disclosed.

  However, in the panel having the structure of Patent Document 1, since both side edge plates of the first surface plate and the second surface plate are in an overlapped state inside and outside, a half surface that can be surely positioned in the horizontal direction, inevitably outside Since the end edge of the side edge plate located at the exposed portion is exposed, an edge member made of an aluminum extrusion mold must be screwed separately to both end faces in order to conceal it. The edge plates on both sides of the first surface plate and the second surface plate are also firmly connected by the screws for attaching the edge members, but the presence of this edge member reduces the number of parts and assembly man-hours. This was a great hindrance in reducing manufacturing costs.

  Further, as disclosed in Patent Document 2, it is known to attach a synthetic resin foot guard to a lower end carner portion of a panel body that moves while floating from the floor surface.

Japanese Patent No. 3976013 Utility Model Registration No. 3007254

  Therefore, in view of the above-described situation, the present invention intends to solve a structure in which a core material such as a paper honeycomb is sandwiched between the first surface plate made of steel and the second surface plate, and the surface plates are connected to each other. The lightweight door panel is excellent in appearance even without attaching edge members to both side end faces, and the positioning when connecting the first surface plate and the second surface plate is accurate, and it is easy to manufacture with few assembly steps. It is in the point of providing the lightweight door panel which can be made, and can aim at reduction of manufacturing cost, and its manufacturing method.

  In order to solve the above-mentioned problem, the present invention is a lightweight door panel in which a core material is sandwiched between a first surface plate and a second surface plate and bonded to each other via the core material. The second surface plate is bent inwardly at a right angle around the decorative plate that forms the surface to form an upper edge plate, a lower edge plate, and both side edge plates, and the edges of each edge plate are perpendicular to each other. Bending to form a reinforcing plate parallel to the decorative plate, further bending the inner edge of both side reinforcing plates at a right angle to form a bent plate parallel to the side edge plate, The reinforcing plates of the first surface plate and the second surface plate are butt-joined to each other, and at least the lower end on the door end side covers the surface and the lower end of the side edge plate of the first surface plate and the second surface plate, and the both sides A synthetic resin cover member for positioning the edge plate is mounted, and the core material is placed between the decorative plates of the first surface plate and the second surface plate. Was constructed lightweight door panel, characterized in that it has adhered to (claim 1).

Here, the edge portions of the upper edge plate and the lower edge plate on the door end side of the first surface plate and the second surface plate are cut out, and are opened up and down when the first surface plate and the second surface plate are joined. was openings formed in the upper and lower portions, said cover member, said first face sheet and the second surface plate both side edges plate, the ends and the surface of the both side edges plate on both sides a reinforcing plate and both bent plate The cover part which covers a lower end part and the fitting part which positions the said 1st surface board and a 2nd surface board by mounting | wearing using the said lower opening part are provided (Claim 2).

Further, the cover part of the cover member is formed by raising and forming a tip cover piece that abuts the lower end of the surface of the side plate on both sides of the first surface plate and the second surface plate at the end of the base part, A plurality of protrusions that contact the inner surface of the decorative plate and the side edge plate of the first surface plate and the second surface plate, and the engagement that contacts the inner surface of both folded plates in the lower opening A piece is formed, and an engaging claw is juxtaposed on the contact surface side of the engaging piece, and the engaging claw is pulled out at the lower end of each bent plate of the first surface plate and the second surface plate It is more preferable that the engagement holes to be engaged with each other are formed.

  A box-shaped reinforcing bracket for attaching a hinge for opening and closing is arranged at the upper and lower corners on the door bottom side of the first surface plate and the second surface plate in a state where the side portions and the upper and lower portions are in contact with each other and positioned. It is also preferable that the two decorative plates are bonded to each other (claim 4).

The present invention also relates to a method for manufacturing a lightweight door panel in which a core material is sandwiched between a first surface plate and a second surface plate and bonded to each other via the core material, the first surface plate and the second surface plate. The face plate is bent inwardly at a right angle around the decorative plate to form a top edge plate, a lower edge plate, and both side edge plates, and the edge of each edge plate is bent at a right angle. Forming a reinforcing plate parallel to the decorative plate, bending the inner edges of both side reinforcing plates at right angles to form a bent plate parallel to the side edge plate, and 2 Ends of the upper edge plate and the lower edge plate on the door end side of the front surface plate are cut out, and openings that are opened up and down when the first surface plate and the second surface plate are joined are formed in the upper and lower portions. The upper reinforcing metal fitting and the lower reinforcing metal, which are mounted on the bench with the decorative plate of the first surface plate facing down, and adhesive is applied to the upper and lower corners on the door bottom side of the decorative plate Then, after placing the core material coated with adhesive on both the front and back surfaces on the decorative plate of the first surface plate, the second surface plate is placed with the decorative plate up, and the first surface plate The reinforcing plates of the surface plate and the second surface plate are butt-joined to each other, and a cover member made of synthetic resin is attached using the lower opening on the door end side, so that the first surface plate and the second surface plate Covers the surface and bottom edge of the side edge plate, positions the side edge plates, and sandwiches the side edge plates of the first surface plate and the second surface plate using the upper opening on the door end side. The upper fixing tool for positioning is detachably mounted, and the upper decorative tool is removed after the first face plate and the second face plate are bonded together via the core material. A lightweight door panel manufacturing method is provided.

Here, the cover member includes a cover portion that covers both side edge plates of the first surface plate and the second surface plate, end portions of the both side reinforcing plates and both folded plates, and a lower end surface of the both side edge plates. A fitting portion for positioning the first surface plate and the second surface plate by mounting using the lower opening, and the cover portion is connected to the first surface plate at an end portion of a base portion. A tip cover piece that abuts against the lower end of the surface of both side edge plates of the second surface plate is raised and formed, and the fitting portion has a makeup of the first surface plate and the second surface plate within the lower opening. A plurality of protrusions that contact the inner surface of the plate and the side edge plate and an engaging piece that contacts the inner surface of both folded plates are formed, and an engaging claw is provided in parallel on the contacting surface side of the engaging piece. It is more preferable that an engagement hole for retaining and engaging the engagement claw is formed at the lower end of each bent plate of the first surface plate and the second surface plate. Shii (claim 6).

  The lightweight door panel of the invention according to claim 1 as described above is a lightweight door panel formed by sandwiching a core material between a first surface plate and a second surface plate and bonding them to each other through the core material. The first surface plate and the second surface plate are bent inward at a right angle around the decorative plate serving as a surface to form an upper edge plate, a lower edge plate, and both side edge plates, and the edge of each edge plate Is bent at a right angle to form a reinforcing plate parallel to the decorative plate, and the inner edges of both side reinforcing plates are bent at a right angle to form a bent plate parallel to the side edge plate. Yes, the reinforcing plates of the first surface plate and the second surface plate are butt-joined to each other, and at least the lower end on the door end side covers the surface and the lower end of the side edge plate of the first surface plate and the second surface plate. A cover member made of a synthetic resin for positioning the side edge plates is attached, and both the first surface plate and the second surface plate are decorated. Since the gaps are bonded via the core material, the reinforcing plates formed around the first surface plate and the second surface plate are butted and joined together, and the two decorative plates are bonded via the core material. Regardless of the structure, positioning can be performed with the cover member attached to the lower end on the door end side, so there is no step on the side edge plate, and the cover member has excellent appearance without the need to install an edge member. Since it covers the lower end of the door side, it also functions as a foot guard.

According to claim 2, when the edge portions of the upper edge plate and the lower edge plate on the door end side of the first surface plate and the second surface plate are notched, and the first surface plate and the second surface plate are joined. Opening portions that are open upward and downward are formed in the upper and lower portions, and the cover member includes both side edge plates of the first surface plate and the second surface plate, both side reinforcing plates, and end portions and both side portions of both folded plates. Since the cover part which covers the surface lower end part of an edge plate and the fitting part which positions the said 1st surface plate and a 2nd surface plate by mounting | wearing using the said lower opening part were provided, the 1st surface plate When the first surface plate and the second surface plate are joined, the first surface plate and the second surface plate are positioned by fitting the fitting portion of the cover member into the lower opening formed at the lower end portion on the door end side. And the cover part of the cover member has both side edge plates of the first surface plate and the second surface plate, both side reinforcing plates and both ends of the folded plates and both side edges. By covering the surface lower end portion of, it is to combine the function of the increase and foot guards appearance.

According to a third aspect of the present invention, the cover portion of the cover member is formed such that a tip cover piece that abuts the lower end portions of the front edge surfaces of both the first surface plate and the second surface plate is raised at the end portion of the base portion. The fitting portion includes a plurality of protrusions that contact the inner surfaces of the decorative plate and the side edge plate of the first surface plate and the second surface plate in the lower opening , and the inner surfaces of both folded plates. And an engagement claw is provided in parallel on the contact surface side of the engagement piece, and the lower end portion of each bent plate of the first surface plate and the second surface plate is formed with the engagement piece. by obtained by forming engaging holes for retaining engagement of the engaging claw, respectively, can be mounted by simply interpolating fit the fitting portion of the cover member to the lower opening in the retaining state, thereby the The edge plates on both sides of the first surface plate and the second surface plate can be joined without any step, and the lower end on the door end side constitutes the cover portion of the cover member. Base portion and the tip cover piece and in can completely cover the improvement and foot guard functions appearance can be reliably fulfill.

  According to the fourth aspect, the box-shaped reinforcing bracket for attaching the hinge for opening and closing is positioned by contacting the upper and lower portions to the upper and lower corner portions on the door bottom side of the first surface plate and the second surface plate. Since it is arranged in a state and bonded to both decorative plates, when the decorative plates of the first surface plate and the second surface plate are bonded to each other through the core material, the door bottom side is positioned by the upper and lower reinforcing metal fittings. The door side can be positioned with the cover member, and can be bonded to the first surface plate and the second surface plate in an accurate state, and the side edge plates on both end faces are flush with each other. Even if the edge member is not made, the appearance is excellent.

  Moreover, according to the method for manufacturing a lightweight door panel according to claim 5 of the present invention, the decorative plate of the first surface plate is placed on the bench facing down, and the adhesive is applied to the upper and lower corners on the door bottom side of the decorative plate. After the applied upper reinforcing metal fitting and lower reinforcing metal fitting are placed and positioned, and then the core material coated with adhesive on both the front and back surfaces is placed on the decorative plate of the first surface plate, the second surface plate is attached to the decorative plate. The first reinforcing plate and the reinforcing plate of the first surface plate and the second surface plate are butt-joined to each other, and a cover member made of synthetic resin is attached using the lower opening on the door end side, Cover the surface and bottom edge of the side edge plate of the first surface plate and the second surface plate, position the side edge plates, and further use the upper opening on the door end side to make the first surface plate and the second surface plate. An upper fixture for positioning by sandwiching a side edge plate of the face plate is detachably attached to the first surface. Since the upper fixture is removed after bonding the two decorative plates of the first surface plate and the second surface plate, the first surface plate is excellent in appearance without attaching edge members to both end surfaces. The positioning when connecting the second surface plate and the second surface plate is accurate, the number of assembling steps is small, it can be easily manufactured, and the manufacturing cost can be reduced.

According to a sixth aspect of the present invention, the cover member includes the side edge plates of the first surface plate and the second surface plate, the end portions of the both side reinforcing plates and the bent plates, and the lower end surfaces of the side edge plates. A cover portion for covering and a fitting portion for positioning the first surface plate and the second surface plate by mounting using the lower opening are provided, and the cover portion is provided at the end of the base portion. A front end cover piece that abuts on the lower end of the front surface of both side edge plates of the first surface plate and the second surface plate is formed upright, and the fitting portion has the first surface plate and the second surface within the lower opening . A plurality of protrusions that contact the inner surface of the decorative plate and the side edge plate of the face plate and an engagement piece that contacts the inner surface of both folded plates are formed, and are engaged with the contact surface side of the engagement piece. Claws are arranged side by side, and engagement holes for retaining and engaging the engagement claws are formed at the lower ends of the bent plates of the first surface plate and the second surface plate, respectively. The first surface plate in which the cover member can be securely attached by simply fitting the fitting portion into the lower opening of the first surface plate and the second surface plate in the butt joint state, and the adhesive is uncured. And the second surface plate can be maintained in an accurately positioned state, and the lower end portion of the door end side can be completely covered, so that the cover member remains attached even after the adhesive has dried and hardened. This fulfills the function of the foot guard at the lower end of the door panel on the door end side.

It is a front view of the lightweight door panel which concerns on this invention. It is a perspective view of a 1st surface board and a 2nd surface board. It is a perspective view which shows the 1st process of the manufacturing method of the lightweight door panel which concerns on this invention. It is a perspective view which similarly shows the 2nd process of the manufacturing method of a lightweight door panel. It is a perspective view which similarly shows the 3rd process of the manufacturing method of a lightweight door panel. It is a perspective view which similarly shows the 4th process of the manufacturing method of a lightweight door panel. It is a fragmentary perspective view of the state which mounts an upper fixture on the upper part by the side of a door. It is a fragmentary perspective view in the state where a cover member is attached to the lower part on the door end side. It is a fragmentary sectional view in the state where a cover member was installed. The cover member is shown, (a) is a front view, (b) is a right side view, (c) is a plan view, (d) is a sectional view, and (e) is a perspective view. An upper fixture is shown, (a) is a front view, (b) is a right side view, (c) is a plan view, (d) is a cross-sectional view, and (e) is a perspective view.

  Next, the present invention will be described in more detail based on the embodiments shown in the accompanying drawings. FIG. 1 is an overall view of a lightweight door panel according to the present invention, FIG. 2 shows a first surface plate and a second surface plate, FIGS. 3 to 9 show manufacturing steps, FIG. 10 shows a cover member, and FIG. In the figure, reference numeral 1 denotes a first surface plate, 2 denotes a second surface plate, 3 denotes a core material, 4 denotes a reinforcing bracket, 5 denotes an opening / closing mechanism bracket, 6 denotes a cover member, and 7 denotes an upper fixture. Each is shown. In addition, in this embodiment, since the dimension of the 1st surface plate 1 and the 2nd surface plate 2 is reduced and shown, the other members are displayed relatively large.

  The lightweight door panel according to the present invention sandwiches a lightweight core 3 between a first surface plate 1 and a second surface plate 2 made of steel, and has box-shaped reinforcing brackets 4, 4 at upper and lower corners on the door bottom side. It has a structure in which an opening / closing mechanism bracket 5 is mounted in the upper and lower middle part on the door end side, and an opening / closing hinge (not shown) is attached to the upper and lower ends using the reinforcing brackets 4 and 4 at least. The opening / closing mechanism bracket 5 is used to attach a knob and a locking device (both not shown), and the positioning of the first surface plate 1 and the second surface plate 2 at the time of manufacture and the foot guard at the lower end of the door end side. This is a basic structure equipped with a cover member 6 that also serves as a part. Further, the upper fixture 7 is attached to the upper end portions of the first surface plate 1 and the second surface plate 2 on the door end side and used for positioning only at the time of manufacture. Here, the reinforcing metal fitting 4 installed in the upper part is indicated as “upper reinforcing metal fitting 4A”, and the reinforcing metal fitting 4 provided in the lower part is indicated as “lower reinforcing metal fitting 4B”, but in this embodiment, the upper reinforcing metal fitting 4A and the lower reinforcing metal fitting are provided. 4B is a member having exactly the same shape, and can be used as the lower reinforcing metal fitting 4B if the upper reinforcing metal fitting 4A is turned upside down.

  As shown in FIG. 2, the first surface plate 1 is bent inwardly at a right angle around the decorative plate 8 serving as a surface, and an upper edge plate 9, a lower edge plate 10, and both side edge plates 11, 12 are provided. And the reinforcing plates 9A, 10A, 11A, 12A parallel to the decorative plate 8 are formed by bending the edge of each of the edge plates 9-12 at a right angle, and the side reinforcing plates 11A, 12A are further formed. Are bent at right angles to form the bent plates 11B and 12B parallel to the side edge plates 11 and 12, respectively. Here, an upper reinforcing plate 9A is formed on the upper edge plate 9, a lower reinforcing plate 10A is formed on the lower edge plate 10, and a side reinforcing plate 11A and a bent portion are formed on the side edge plate 11 on the door end side. A plate 11B was formed, and a side reinforcing plate 12A and a bent plate 12B were formed on the side edge plate 12 on the door butt side. And the edge part of the upper edge board 9 and the lower edge board 10 by the side of the door of the said 1st surface board 1 is notched, and the upper and lower end edge of the side edge board 11, the side reinforcement board 11A, and the bending board 11B is made. It is exposed. In the figure, reference numeral 13 denotes an upper notch, and 14 denotes a lower notch. The surfaces of the reinforcing plates 9A, 10A, 11A, and 12A are set to be the same plane.

  The second surface plate 2 is a mirror image symmetrical shape of the first surface plate 1 and is bent inwardly at a right angle around the decorative plate 15 serving as a surface to form an upper edge plate 16, a lower edge plate 17, and both sides. The edge plates 18 and 19 are formed, and the edges of the edge plates 16 to 19 are bent at right angles to form reinforcing plates 16A, 17A, 18A and 19A parallel to the decorative plate 15, respectively. The inner edges of the part reinforcing plates 18A and 19A are bent at right angles to form bent plates 18B and 19B parallel to the side edge plates 18 and 19, respectively. Here, an upper reinforcing plate 16A is formed on the upper edge plate 16, a lower reinforcing plate 17A is formed on the lower edge plate 17, and a side reinforcing plate 18A and a bent portion are formed on the side edge plate 18 on the door end side. A plate 18B is formed, and a side reinforcing plate 19A and a bent plate 19B are formed on the side edge plate 19 on the door bottom side. In the same manner as described above, the upper edge plate 16 and the lower edge plate 17 on the door end side of the second surface plate 2 are notched to form an upper notch portion 20 and a lower notch portion 21.

  And the lightweight door panel which concerns on this invention butt-joins each reinforcement board 9-12 of the said 1st surface board 1, and each reinforcement board 16-19 of the 2nd surface board 2, and is at least at the lower end of the door-end side. A cover member 6 made of a synthetic resin that covers the surface and the lower end of the side edge plate 11 of the first surface plate 1 and the side edge plate 18 of the second surface plate 2 and positions the side edge plates 11 and 18 is provided. Attach and bond the decorative plates 8 and 15 of the first surface plate 1 and the second surface plate 2 through the core material 3. As the core material 3, a paper honeycomb is used, and the hexagonal holes of the honeycomb are oriented in the thickness direction of the panel. Therefore, although it has a very high compressive strength, it is made of paper and is lightweight. .

  Here, when the first surface plate 1 and the second surface plate 2 are joined together, an upper opening 22 opened upward by the upper notches 13 and 20 is formed and opened downward by the lower notches 14 and 21. Since the lower upper opening 23 is formed, the cover member 6 is mounted using the lower opening 23. The cover member 6 includes both side edge plates 11 and 18 of the first surface plate 1 and the second surface plate 2, end portions of both side reinforcing plates 11A and 18A, and both bent plates 11B and 18B, and both side edge plates. 11 and 18 are provided with a cover portion 24 that covers the lower end portions of the surface and a fitting portion 25 that fits into the lower opening 23 and positions the first surface plate 1 and the second surface plate 2.

  More specifically, as shown in FIGS. 8 and 10, the cover portion 24 of the cover member 6 is formed at the end portion of the base portion 26 on both side edge plates 11 of the first surface plate 1 and the second surface plate 2. A front end cover piece 27 that is in contact with the lower end portion of the front surface 18 is formed upright, and the fitting portion 25 includes a decorative plate 8 of the first surface plate 1 and the second surface plate 2 in the lower opening 23. 15 and a plurality of projections 28 that come into contact with the inner surfaces of the side edge plates 11 and 18, and an engagement piece 29 that comes into contact with the inner side surfaces of both folded plates 11B and 18B. The engaging claws 30 are arranged side by side on the contact surface side, and the engaging claws 30 are provided at the lower ends of the bent plates 11B and 18B of the first surface plate 1 and the second surface plate 2, respectively. Engagement holes 31 and 31 for retaining and engaging 30 are formed.

  As shown in FIG. 10, the cover part 24 of the cover member 6 has a base part 26 and a tip cover piece 27 that are L-shaped in side view, and the base part 26 is formed with the first surface plate 1 and the second surface plate 2. The both side edge plates 11, 18 of the surface plate 2 and the lower ends of the decorative plates 8, 15 are abutted and covered, and the tip cover pieces 27 are on both sides of the first surface plate 1 and the second surface plate 2. The edge plates 11 and 18 are in contact with the lower end of the surface and cover that portion. As shown in FIGS. 9 and 10, the protrusions 28 of the cover member 6 are formed on the decorative plate 8 of the first surface plate 1, the corner portion inner surface of the side edge plate 11, and the decorative surface of the second surface plate 2. Corner projections 28A and 28A that contact the plate 15 and the corner portion of the side edge plate 18, the inner surface of the side edge plate 11 at a position close to the side reinforcing plate 11A of the first surface plate 1, and the second table It consists of intermediate projections 28B and 28B that come into contact with the inner surface of the side edge plate 18 at a position close to the side reinforcing plate 18A of the face plate 2. And the lower end part of the both-sides edge board 11 and 18 is clamped by the said front-end | tip cover piece 27, corner protrusion 28A, 28A, and intermediate | middle part protrusion 28B, 28B, and each of said 1st surface plate 1 and 2nd surface plate 2 Engagement pieces 29 come into contact with the inner surfaces of the bent plates 11B and 18B, and the engaging pieces 29 and the tip cover piece 27 are folded with the side reinforcing plate 11A, the bent plate 11B and the side reinforcing plate 18A. The curved plates 18B are sandwiched and positioned so that the surfaces of the side reinforcing plates 11A and 18A are flush with each other, and the engaging claws 30 and 30 provided on the engaging pieces 29 are connected to the bent plates 11B and 18B. Engage with the joint holes 31, 31 in a retaining state. This cover member 6 is attached to the lower end portion of the door panel on the door end side and also has a function as a foot guard.

  Further, by using the upper opening 22 formed when the first surface plate 1 and the second surface plate 2 are joined, the cover member 6 is mounted with the same fitting structure as described above. Although it is possible to perform the positioning function, in the present invention, the upper end 7 on the door end side is detachably attached to the upper fixture 7. As shown in FIGS. 7 and 11, the upper fixture 7 includes a reference block 32 that comes into contact with the upper end portions of the surface edge plates 11 and 18 of the first surface plate 1 and the second surface plate 2 from the outside. The holding block 33 is inserted into the upper opening 22 and the lower part is inserted into the reference block 32. The bolt 34 and the wing nut 35 are used to fasten both blocks. A stepped portion 36 is formed on the upper portion of the reference block 32, a convex portion 37 that engages with the stepped portion 36 is formed on the upper portion of the clamping block 33, and the convex portion of the clamping block 33 is connected to the bolt 34. 37 is passed through the upper portion of the reference block 32, the wing nut 35 is screwed into the protruding portion, and the lower portion of the clamping block 33 is inserted into the upper opening portion 22, and the first face plate 1 and A pair of sandwiching portions 38 and 38 are formed in contact with the leading edges of the bent plates 11B and 18B of the second surface plate 2. A mounting hole 39 penetrating the inside and outside of the reference block 32 is formed, a magnet 40 is inserted into the mounting hole 39, and a fixing screw 41 communicates with the mounting hole 39 on one side surface and a lower surface of the reference block 32. The outer periphery of the magnet 40 is pressed and fixed to the screw holes 42 and 42 formed in this manner.

  Then, in a state where the first surface plate 1 and the second surface plate 2 are accurately positioned and joined, the reference block 32 of the upper fixture 7 is joined to the upper ends of the side edge plates 11 and 18. The magnet 40 is attracted across the side edge plates 11, 18, and both the sandwiching portions 38, 38 of the sandwiching block 33 are inserted into the upper opening 22, and each fold between the sandwiching portions 38, 38 is folded. The leading edges of the curved plates 11B and 18B are sandwiched, and the wing nut 35 is tightened to firmly clamp the upper ends of the side edge plates 11 and 18 between the reference block 32 and the sandwiching portions 38 and 38. In this state, since the surfaces of the side edge plates 11 and 18 are flush with each other, the first surface plate 1 and the second surface plate 2 are maintained in an accurately bonded state.

  In order to assemble the lightweight door panel according to the present invention, as shown in FIG. 3 (first step), first, the decorative plate 8 of the first surface plate 1 is placed on the bench with the bottom face up and down. The upper reinforcing metal fitting 4A and the lower reinforcing metal fitting 4B coated with an adhesive are placed on the corner portion, and one side and the upper part of the upper reinforcing metal fitting 4A are positioned in contact with the side reinforcing plate 12 and the upper reinforcing plate 9, and the lower portion One side part and the lower part of the reinforcing metal fitting 4B are positioned in contact with the side part reinforcing plate 12 and the lower reinforcing plate 10. Further, the opening / closing mechanism fitting 5 in which an adhesive is applied to the upper and lower intermediate portions of the first surface plate 1 on the door end side is brought into contact with the bent plate 11B and positioned. Here, in order to attach and pull out hinges to the upper reinforcing metal fitting 4A and the lower reinforcing metal fitting 4B, a part of the upper edge plate 9 and the lower edge plate 10 are cut out, and the lock attached to the opening / closing mechanism metal fitting 5 is provided. A part of the upper and lower intermediate portions of the side edge plate 11 is notched in order to pull out a locking rod or a latch that protrudes and moves sideways in conjunction with a tool or a knob.

  Then, as shown in FIG. 4 (second step), a portion of the back surface of the decorative plate 8 of the first surface plate 1 provided with the upper reinforcing metal fitting 4A, the lower reinforcing metal fitting 4B, and the opening / closing mechanism metal fitting 5 is provided. Except for the whole surface, the core material 3 coated with an adhesive is spread on both the front and back surfaces. Then, as shown in FIG. 5 (third step), the second surface plate 2 is placed with the decorative plate 15 facing upward, and the second surface plate is placed on each of the reinforcing plates 9A to 12A of the first surface plate 1. The reinforcing plates 16A to 19A of the face plate 2 are butt-joined. At this time, the upper reinforcing metal fitting 4A and the lower reinforcing metal fitting 4B are in close contact with the upper and lower corners on the door bottom side of the second surface plate 2, and the opening / closing mechanism metal fitting 5 is on the door tip side of the second surface plate 2. It is positioned in contact with the side edge plate 18.

  After that, as shown in FIGS. 6 (fourth process) and FIG. 7, the both holding portions 38, 38 of the upper fixture 7 in a state where the wing nut 35 is loosened in the upper opening 22 are respectively attached to the bent plates 11B, 18B. The side edge plates 11 and 18 are firmly held between the reference block 32 and the holding portions 38 and 38 of the holding block 33 by tightening the wing nut 35 and inserting it in close contact with the outside of the edge. Further, as shown in FIGS. 6 and 8, the fitting portion 25 of the cover member 6 is fitted and inserted into the lower opening portion 23, and the corner projections 28 </ b> A and 28 </ b> A constituting the fitting portion 25 are formed on the first surface plate 1. The corner portions of the decorative plate 8 and the side edge plate 11, the decorative plate 15 of the second surface plate 2, and the corner portions of the side edge plate 18 are pressed against each other, and the intermediate projections 28 </ b> B and 28 </ b> B are attached to the first surface plate 1. The inner surface of the side edge plate 11 near the side reinforcing plate 11A and the inner surface of the side edge plate 18 near the side reinforcing plate 18A of the second surface plate 2 are pressed against each other. The face pieces 1 and 18 are pressed against the lower end portions of the side edge plates 11 and 18 of the face plate 1 and the second face plate 2, and the engagement pieces 29 constituting the fitting portion 25 are connected to the first face plate 1 and the second face plate 2. The engaging claws 30 and 30 provided on the inner surface of the bent plates 11B and 18B and provided on the contact surface side of the bent plates 11B and 18B Retaining engaged to focus on Goana 31 and 31. By attaching the cover member 6 to the lower end portions of the first surface plate 1 and the second surface plate 2 on the door end side, the end edge is completely covered by the base portion 26 and the tip cover piece 27, and The position of the first surface plate 1 and the second surface plate 2 is maintained.

  Finally, although not shown in the drawing, the pressure plate is pressed from above the decorative plate 15 of the second surface plate 2 with a predetermined pressure, and heated appropriately to promote drying of the adhesive. As a result, the decorative plates 8 and 15 are firmly connected to each other via the core material 3, the upper reinforcing metal fitting 4 </ b> A, the lower reinforcing metal fitting 4 </ b> B, and the opening / closing mechanism metal fitting 5. Then, after the adhesive is dried and cured, the press plate is removed, and the upper fixture 7 is removed to complete the lightweight door panel. Here, the cover member 6 is used as a foot guard while being attached to the lower end of the lightweight door panel on the door tip side.

  If the bonding strength between the first surface plate 1 and the second surface plate 2 is insufficient, the upper and lower portions of the first surface plate 1 and the second surface plate 2 can be screwed together with a connecting piece. It is. For this purpose, the upper reinforcing plates 9A and 16A of the first surface plate 1 and the second surface plate 2 are formed with notch holes at positions along the upper edge plates 9 and 16, and the lower reinforcing plates 10A and 17A. Therefore, a notch hole is formed at a position along the lower edge plates 10 and 17. And while joining the said 1st surface plate 1 and the 2nd surface plate 2, while inserting a connection piece in each notch hole, the screw which penetrated the said upper edge plates 9 and 16 and the lower edge plates 10 and 17 was used. It is screwed and connected to both ends of the connecting piece. Here, although the connecting screws are exposed on the upper and lower end surfaces of the door panel, the appearance is not affected at all because the connecting screws are inconspicuous.

1 first surface plate, 2 second surface plate,
3 core material, 4 reinforcing bracket,
4A Upper reinforcement bracket, 4B Lower reinforcement bracket,
5 Opening / closing mechanism bracket, 6 Cover member,
7 upper fixtures, 8 decorative panels,
9 Upper edge plate, 9A Upper reinforcement plate,
10 Lower edge plate, 10A Lower reinforcement plate,
11 side edge plate, 11A side reinforcement plate,
11B bent plate, 12 side edge plate,
12A side reinforcing plate, 12B bent plate,
13 upper notch, 14 lower notch,
15 decorative board, 16 upper edge board,
16A Upper reinforcement plate, 17 Lower edge plate,
17A Lower reinforcing plate, 18 Side edge plate,
18A side reinforcement plate, 18B bent plate,
19 side edge plate, 19A side reinforcement plate,
19B bent plate, 20 upper notch,
21 lower notch, 22 upper opening,
23 lower opening, 24 cover,
25 fitting part, 26 base part,
27 tip cover piece, 28 protrusion,
28A corner projection, 28B middle projection,
29 engaging pieces, 30 engaging claws,
31 engagement hole, 32 reference block,
33 clamping blocks, 34 bolts,
35 Wing nut, 36 Stepped part,
37 convex base part, 38 clamping part,
39 Mounting hole 40 Magnet 41 Fixing screw 42 Screw hole.

Claims (6)

  A lightweight door panel in which a core material is sandwiched between a first surface plate and a second surface plate and bonded to each other via the core material, the first surface plate and the second surface plate being a decorative plate serving as a surface The upper edge plate, the lower edge plate, and the both side edge plates are formed by bending the periphery of the plate inward at a right angle, and the edge plate of each edge plate is bent at a right angle and the reinforcing plate is parallel to the decorative plate Further, the inner edge of both side reinforcing plates is bent at a right angle to form a bent plate parallel to the side edge plate, and each of the first surface plate and the second surface plate is reinforced. A synthetic resin cover that butt-joins the plates and covers the surfaces and lower ends of the side edge plates of the first surface plate and the second surface plate at least at the lower end on the door end side and positions the side edge plates. Lightweight, characterized in that a member is mounted and the decorative plates of the first surface plate and the second surface plate are bonded via the core material. The rear panel. Openings opened up and down when the first surface plate and the second surface plate are cut out at the ends of the upper edge plate and the lower edge plate on the door end side of the first surface plate and the second surface plate. was formed on the upper and lower portion, said cover member, said first face sheet and the second surface plate both side edges plate, the surface lower end of the end portion and the both side edges plate on both sides a reinforcing plate and both bent plate The lightweight door panel according to claim 1, further comprising: a cover portion that covers and a fitting portion that positions the first surface plate and the second surface plate by mounting using the lower opening . The cover part of the cover member is formed by standing up and forming a tip cover piece that comes into contact with the lower end of the surface of both side edge plates of the first surface plate and the second surface plate at the end of the base portion. A plurality of protrusions that contact the inner surfaces of the decorative plate and the side edge plate of the first surface plate and the second surface plate in the lower opening, and the engagement pieces that contact the inner surfaces of both folded plates. The engaging claw is arranged in parallel on the contact surface side of the engaging piece, and the engaging claw is retained at the lower end of each bent plate of the first surface plate and the second surface plate. 3. The lightweight door panel according to claim 2, wherein engaging holes are formed respectively.   A box-shaped reinforcing bracket for attaching a hinge for opening and closing is disposed at the upper and lower corners on the door butt side of the first surface plate and the second surface plate in a state where the side portion and the upper and lower portions are in contact and positioned. The lightweight door panel of any one of Claims 1-3 formed by adhere | attaching a decorative board. A lightweight door panel manufacturing method in which a core material is sandwiched between a first surface plate and a second surface plate and bonded to each other via a core material, the first surface plate and the second surface plate having a surface, The upper edge plate, the lower edge plate and the both side edge plates are formed by bending the periphery of the decorative plate inward at a right angle, and the edge of each edge plate is bent at a right angle to be parallel to the decorative plate. A reinforcing plate is formed, and the inner edges of both side reinforcing plates are bent at a right angle to form a bent plate parallel to the side edge plate, and the doors of the first surface plate and the second surface plate The upper edge plate and the lower edge plate on the side are notched, and an opening that opens up and down when the first surface plate and the second surface plate are joined is formed in the upper and lower portions . Place the face plate on the bench with the face plate facing down, and place the upper and lower reinforcement brackets with adhesive applied to the upper and lower corners on the door bottom side of the face plate. Then, after placing the core material coated with adhesive on both the front and back surfaces on the decorative plate of the first surface plate, the second surface plate is placed with the decorative plate up, and the first surface plate and the first surface plate Side plate of the first surface plate and the second surface plate by butt-joining each reinforcing plate of the two surface plates and attaching a synthetic resin cover member using the lower opening on the door end side The both side edge plates are positioned and the side edge plates are positioned by using the upper opening on the door end side, and the side edge plates of the first surface plate and the second surface plate are sandwiched. A lightweight door panel, wherein an upper fixture is detachably mounted, and the first and second face plates are bonded to each other through the core, and then the upper fixture is removed. Manufacturing method. Said cover member, said first face sheet and the second surface plate both side edges plate, and a cover portion covering an end portion and a surface lower end portion of the both side edges plate on both sides a reinforcing plate and both bent plate, the lower A fitting portion for positioning the first surface plate and the second surface plate is provided by mounting using an opening, and the cover portion has the first surface plate and the second surface at the end of the base portion. A front end cover piece that abuts against the lower end of the surface of both side edge plates of the face plate is formed upright, and the fitting portion includes a decorative plate and a side of the first surface plate and the second surface plate within the lower opening. Forming a plurality of protrusions that contact the inner surface of the edge plate and an engaging piece that contacts the inner surface of both folded plates, and an engaging claw provided in parallel on the contact surface side of the engaging piece, 6. The lightweight door according to claim 5, wherein an engagement hole for retaining and engaging the engagement claw is formed at a lower end portion of each bent plate of the first surface plate and the second surface plate. Method of manufacturing a panel.

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