JP7476013B2 - Plate-shaped building material and method for manufacturing plate-shaped building material - Google Patents

Description

This disclosure relates to a plate-shaped building material and a method for manufacturing the plate-shaped building material.

2. Description of the Related Art Conventionally, plate-shaped building materials have been used for fittings for opening and closing openings in walls, partition walls for dividing rooms, and the like.
The plate-shaped building material ("door" in the text) described in Patent Document 1 is a so-called four-sided frame door. The plate-shaped building material includes a rectangular door frame, a rectangular frame that borders the inner periphery of the door frame, and a rectangular panel that is held by the frame at its four sides. Since the opening on the inside of the frame is rectangular, the non-end faces of the panel are exposed in a rectangular shape.

In the case of the plate-shaped building material described in Patent Document 1, the frame is fixed to the inner circumference of the door frame by pin tacker fastenings or screws. The pin nails or screws are driven into the frame and door frame from the inner circumference side of the frame, so they are not noticeable.

In order to improve the design of plate-shaped building materials, the exposed portion of the end panel may be made non-rectangular.
The plate-shaped building material (referred to as "door" in the text) described in Patent Document 2 is a so-called two-sided frame door. The plate-shaped building material comprises a pair of vertical frames, each of which is a rectangular plate, and a rectangular end panel. Two opposing sides of the end panel are held by the pair of vertical frames, and the exposed portion of the end panel is rectangular. The plate-shaped building material further comprises a plate-shaped covering member. The covering member is bonded to the end panel so as to partially cover the non-end faces of the end panel. As a result, the exposed portion of the end panel can be made non-rectangular.

Japanese Patent Application Laid-Open No. 8-199919 JP 2010-84376 A

In the plate-shaped building material described in Patent Document 2, the surface designs of adjacent vertical frames and covering members are made substantially the same to reduce the sense of incongruity in appearance. However, since the boundaries between the vertical frames and covering members are not concealed, there is a risk that the design may be impaired.
In the case of the plate-shaped building material described in Patent Document 1, by using a frame whose inner opening is non-rectangular, the exposed portion of the panel can be made non-rectangular without using a covering member.

However, because the frame is pin-tacker- or screw-attached to the door frame, the dimensions of the frame in the direction in which the pins or screws are driven are limited by the dimensions of the pins or screws. In the plate-shaped building material described in Patent Document 1, the pins or screws are driven into the frame from the inner periphery of the frame, so the shape of the frame is limited. Therefore, it is difficult to improve the freedom of shape of the exposed part of the panel, and therefore difficult to improve the design.

The purpose of this disclosure is to provide a plate-shaped building material and a method for manufacturing the plate-shaped building material that can improve design.

The plate-shaped building material disclosed herein comprises a rectangular mirror panel and a retaining member holding one side of the mirror panel, the retaining member having a convex portion on its peripheral surface facing the end face of the one side, a straight rod-shaped core material along the end face, two retaining plates having the convex portion and the one side sandwiched between their respective one sides and fixed to the core material by a plurality of fixing members driven in from the other side of each of the two retaining plates, and two surface panels attached to the core material and the two retaining plates so as to cover the core material, the two retaining plates, and the fixing members from the other side of each of the two retaining plates.
The plate-shaped building material disclosed herein comprises a rectangular mirror panel and a retaining member that holds one side of the mirror panel, the retaining member having a convex portion on its peripheral surface facing the end face of the one side and including a straight rod-shaped core material that follows the end face, two retaining plates that have the convex portion and the one side sandwiched between their respective one sides and are fixed to the core material by a plurality of fixing members that are driven in from the other side of each of the retaining plates, and two surface panels that are attached to the frame body and the two retaining plates so as to cover the frame body , the two retaining plates, and the fixing members from their respective other sides.

In the present disclosure, the holding member holds one side of the rectangular end plate. The holding member includes a straight rod-shaped core material, two holding plates each having a plate-like shape, and two surface plates each having a plate-like shape.
The core member is disposed along an end surface of one side of the head plate. The core member has a protrusion on its circumferential surface, and the protrusion faces the end surface of one side of the head plate.
The convex portion of the core material and one side of the end plate are sandwiched between one surface of each of the two holding plates.

The two holding plates are fixed to the core by a plurality of fixing members.
The fixing members are driven into the two holding plates and the core material from the other side of each of the two holding plates. Therefore, the dimensions of the holding plates in the direction perpendicular to one side of the holding plates are not limited by the dimensions of the fixing members. This improves the degree of freedom in designing the range in which the holding plates hold the end plate. As a result, it improves the degree of freedom in the shape of the part of the end plate exposed from the holding plate.

The two surface plates cover the core material, the two holding plates, and the fixing members from the other side of each of the two holding plates, so that the boundary between the core material and the holding plates is also concealed by the surface plates.
As a result of the above, the design of the plate-shaped building material can be improved.

The method of manufacturing a plate-shaped building material according to the present disclosure includes preparing a rectangular end plate, a straight rod-shaped core material having a convex portion protruding from the periphery in a direction perpendicular to the length direction, the convex portion having a length in a direction perpendicular to both the protruding direction and the length direction equal to the thickness of the end plate, two holding plates, two surface plates, and a plate-shaped spacer having a thickness equal to the thickness of the end plate, and sandwiching the convex portion and the spacer between one surfaces of the two holding plates, and attaching a fixing member from the other surface side of each of the two holding plates to the two holding plates and the core material. The method is characterized in that the two retaining plates are fixed to the core material by driving them into the core material, the two surface plates are attached to the core material and the two retaining plates so that the core material, the two retaining plates and the fixing member are covered from the other side of each of the two retaining plates with the two surface plates, the spacer is removed from between the two retaining plates, and the one side portion is sandwiched between the two retaining plates by inserting the mirror plate between the two retaining plates with the end face of the one side portion of the mirror plate facing the convex portion.
The method for manufacturing a plate-shaped building material according to the present disclosure includes preparing a rectangular mirror plate, a frame including a straight rod-shaped core material having a convex portion protruding from the periphery in a direction perpendicular to the length direction, the convex portion having a length in a direction perpendicular to both the protruding direction and the length direction equal to the thickness of the mirror plate , two holding plates, two surface plates, and a plate-shaped spacer having a thickness equal to the thickness of the mirror plate, and sandwiching the convex portion and the spacer between one surfaces of the two holding plates, and attaching a fixing member to the two holding plates and the spacer from the other surface side of each of the two holding plates. The two retaining plates are fixed to the core material by driving them into the core material, the two surface plates are attached to the frame body and the two retaining plates so that the frame body, the two retaining plates and the fixing member are covered from the other side of each of the two retaining plates with the two surface plates, the spacer is removed from between the two retaining plates, and the one side portion is sandwiched between the two retaining plates by inserting the mirror plate between the two retaining plates with the end face of the one side portion of the mirror plate facing the convex portion.

In the present disclosure, the manufacturer prepares a rectangular end plate, a straight rod-shaped core material, two holding plates, two surface plates, and a plate-shaped spacer.
The core material has a protrusion. The protrusion protrudes from the peripheral surface of the core material in a direction perpendicular to the length direction of the protrusion. The length of the protrusion in the direction perpendicular to both the protrusion direction of the protrusion and the length direction of the core material is equal to the thickness of the head plate.
The thickness of the spacer is equal to the thickness of the head plate.

The manufacturer sandwiches the convex portion of the core material and the spacer between the first surfaces of the two holding plates and fixes the two holding plates to the core material. At this time, the manufacturer hammers in fixing members from the other surface side of each of the two holding plates into the two holding plates and the core material.
Next, the manufacturer attaches the two surface plates to the core material and the two holding plates such that the two surface plates cover the core material and the two holding plates from the other side of each of the two holding plates.
Since the convex portion of the core material and the spacer are sandwiched between the two holding plates, the distance between the two holding plates can be maintained during the fixing operation using the fixing member and during the installation operation of the surface plate.

Next, the manufacturer removes the spacer from between the two holding plates and inserts the end plate between the two holding plates, with the end face of one side of the end plate facing the protruding portion of the core material.
As a result, the core material, the two holding plates, and the two surface plates function as holding members provided in the plate-shaped building material according to the present disclosure. The holding members hold one side of the end plate. The core material fits along the edge surface of the one side of the end plate.
That is, the method for manufacturing a plate-shaped building material according to the present disclosure can manufacture the plate-shaped building material according to the present disclosure, thereby improving the design of the plate-shaped building material.
Rectangular heads are more readily available and easier to handle than non-rectangular ones.

The manufacturing method of the plate-shaped building material disclosed herein is characterized in that two rectangular retaining plates are prepared, and when the two retaining plates are fixed to the core material, the convex portion is sandwiched between the first sides of each of the two retaining plates, and before removing the spacer from between the two retaining plates, the second sides opposite the first sides of each of the two retaining plates are cut into a predetermined shape together with the two surface panels and the spacer .

In the present disclosure, the manufacturer prepares two retaining plates, each of which has a rectangular shape.
When fixing using the fixing members, the manufacturer sandwiches a spacer between one side of each of the two holding plates, and sandwiches the convex portion of the core material between one side of each of the two holding plates and between the first edges of each of the two holding plates.

Before removing the spacer from between the two holding plates, the manufacturer cuts the second edge of each of the two holding plates, which faces the first edge, into a specified shape together with the two surface plates and spacer. Because the convex portion of the core material and the spacer are sandwiched between the two holding plates, the distance between the two holding plates can be maintained during the cutting process.

Rectangular retaining plates are more readily available and easier to handle than non-rectangular ones.
In addition, the two retaining plates and the two surface plates are formed into a predetermined shape after the core, the two retaining plates, and the two surface plates are fixed together, so that the precision of the shape of the retaining member can be improved compared to when the core, the two retaining plates, and the two surface plates are fixed together after the two retaining plates and the two surface plates are each formed into a predetermined shape.

Furthermore, by preparing multiple work-in-progress holding members before cutting, and cutting each work-in-progress into a different shape, multiple types of holding members can be obtained from one type of work-in-progress.

The manufacturing method of the plate-shaped building material disclosed herein is characterized in that adhesive is injected between the two holding plates before the end plate is inserted between the two holding plates.

In the present disclosure, the adhesive injected between the two holding plates is interposed between each of the two holding plates as the mirror plate is inserted between the two holding plates. The adhesive force of the adhesive can be used to securely hold the mirror plate sandwiched between the two holding plates.

The plate-shaped building material and the method for manufacturing the plate-shaped building material disclosed herein can improve the design of the plate-shaped building material.

FIG. 2 is a front view of the plate-shaped building material according to the embodiment. 2 is a cross-sectional view taken along line II-II in FIG. 1. FIG. 2 is a view of the left vertical frame shown in FIG. 1 with the top panel omitted. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. FIG. 2 is an explanatory diagram of a manufacturing method for a plate-shaped building material. 10 is a cross-sectional view taken along line XX in FIG. 9. FIG. 2 is a cross-sectional view of a plate-shaped building material having two mirror panels.

The following describes an embodiment of the present disclosure. In the following description, the up/down, front/back, and left/right directions are indicated by arrows in the figures.

FIG. 1 is a front view of a plate-shaped building material according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view taken along line II-II in FIG.
In the drawing, reference numeral 1 denotes a plate-shaped building material, which has a rectangular shape that is long in one direction. The plate-shaped building material 1 is used as a door with its length facing up and down.

As shown in Fig. 1, the plate-shaped building material 1 is provided with a gripping portion 11. The gripping portion 11 is disposed on the left side of the front surface (the surface facing the viewer in Fig. 1) of the plate-shaped building material 1, and is located in the center in the up-down direction. As shown in Fig. 2, two gripping portions 11 are provided, one on each side of the plate-shaped building material 1, at positions facing each other in the front-rear direction.
A hinge (not shown) is provided on the right side of the plate-shaped building material 1. The plate-shaped building material 1 is attached to a wall via the hinge so as to be able to open and close an opening provided in the wall.

As shown in Figures 1 and 2, a plate-shaped building material 1 is a two-sided frame door, and includes a panel 2 and two vertical frames 3, 3 (retaining members). In Figure 1, the panel 2 is hatched to make the drawing easier to see.
The mirror panel 2 has a rectangular shape that is long in one direction, and is used with its length and width oriented up and down and left and right. The mirror panel 2 may be either light-transmitting or non-light-transmitting. A light-transmitting mirror panel 2 is made of glass or synthetic resin, for example. A non-light-transmitting mirror panel 2 is made of wood (solid wood or wood material), for example.
Each vertical frame 3 is a rectangular plate that is long in one direction, and is used with its length and width directed up and down and left and right.

The mirror panel 2 is disposed in the center of the plate-shaped building material 1 in the left-right direction, and the vertical frames 3, 3 are disposed on both the left and right sides of the plate-shaped building material 1. In this embodiment, the vertical frame 3 on the left side holds the left side (one side) of the mirror panel 2. On the other hand, the vertical frame 3 on the right side holds the right side (one side) of the mirror panel 2.
In the following, the left vertical frame 3 will be mainly described.

The vertical frame 3 comprises a vertical frame 31 (core material), two supporting plates 32, 32, and two surface plates 33, 33.
FIG. 3 is a diagram of the left vertical frame 3 shown in FIG. 1 with the surface panels 33, 33 omitted.
2 and 3, the vertical frame 31 is in the shape of a straight rod and has a rectangular cross section. The vertical frame 31 is used with its length oriented vertically.
The vertical frame 31 has a protrusion 311. The protrusion 311 protrudes to the right (in a direction perpendicular to the longitudinal direction of the vertical frame 31) from the right side surface (periphery) of the vertical frame 31. The protrusion 311 forms a stripe along the entire length of the vertical frame 31 and has a rectangular cross section. The width of the protrusion 311 (the length in the direction perpendicular to the protruding direction of the protrusion 311 and the longitudinal direction of the vertical frame 31) is equal to the thickness of the end panel 2. The protrusion 311 is located at the center of the right side surface of the vertical frame 31 in the front-to-rear direction.

As shown in FIG. 3 , the vertical frame 3 further includes a vertical frame 301 and two horizontal frames 302 , 302 .
The vertical frame 31, the vertical frame 301, and the horizontal frames 302, 302 constitute a frame body 30 by bridging the horizontal frames 302, 302 across both longitudinal ends of the vertical frame 31 and the vertical frame 301. In this embodiment, the vertical frame 31 is disposed horizontally relative to the horizontal frames 302, 302, and the vertical frame 301 is disposed vertically relative to the horizontal frames 302, 302.

The frame body 30 has a rectangular shape that is long in the length direction of the vertical frame 31, and the horizontal frame 302 is used facing left and right.
The frame body 30 includes a plurality of horizontal beams 303, 303, .... The horizontal beams 303, 303, ... are respectively arranged at appropriate intervals between the vertical frames 31 and 301 in the middle of their length directions.

2 and 3, each holding plate 32 is rectangular and elongated in one direction, with the length and width directions facing up and down and left and right. Both corners of the right side of the holding plate 32 (parts shown by two-dot chain lines in FIG. 3) are cut out to form a smooth concave shape. The holding plate 32 has a vertically symmetrical shape.
The length of the holding plate 32 is equal to the length of the frame body 30. The left end surface of the holding plate 32 is in contact with the right side surface of the vertical frame 31.

The retaining plates 32, 32 face each other in the front-rear direction. The convex portion 311 of the vertical frame 31 and the left edge portion of the mirror plate 2 are sandwiched between the rear surface of the front retaining plate 32 and the front surface of the rear retaining plate 32 (between one surface of each of the retaining plates 32, 32). The convex portion 311 of the vertical frame 31 faces the left end surface (end surface of one side portion) of the mirror plate 2 and is located between the left edges of each of the retaining plates 32, 32. The vertical frame 31 runs along the left end surface of the mirror plate 2. The length by which the convex portion 311 protrudes from the right side surface of the vertical frame 31 is sufficiently smaller than the width of the retaining plate 32.

The end plate 2 is adhered to the tip surface of the convex portion 311 and the mutually opposing surfaces of the holding plates 32, 32 by an adhesive.
The front surface of the front holding plate 32 is flush with the front surface of the frame body 30 , and the rear surface of the rear holding plate 32 is flush with the rear surface of the frame body 30 .

2, the vertical frame 31 and the holding plates 32, 32 are fixed to each other by two fixing members 4, 4. Each fixing member 4 is a U-shaped staple for a tacker.
In the front retaining plate 32, one fixing member 4 is driven from the front (from the front side of the retaining plate 32) backward into the front surface of the retaining plate 32 and the front side surface of the vertical frame 31. Similarly, in the rear retaining plate 32, the other fixing member 4 is driven from the rear into the rear surface of the retaining plate 32 and the rear side surface of the vertical frame 31 forward.
Although not shown, a plurality of fixing members 4, 4, . . . are arranged at appropriate intervals in the longitudinal direction of the vertical frame 31 on the front side of the front holding plate 32 and on the rear side of the rear holding plate 32, respectively.

1 and 2, each surface plate 33 is rectangular and long in one direction, with the length and width directions facing up and down and left and right. The length of the surface plate 33 is equal to the length of the holding plate 32. Both corners of the right side of the surface plate 33 are missing in a smooth concave shape. The shape and dimensions of the missing parts of the surface plate 33 correspond to the shape and dimensions of the missing parts of the holding plate 32.
The surface plates 33, 33 entirely cover the frame 30, the holding plates 32, 32, and the fixing members 4, 4, . . . from both the front and rear, and are attached to the frame 30 and the holding plates 32, 32 with an adhesive.

2, the right end surfaces of the front holding plate 32 and the front surface plate 33 are entirely covered with a tape-like decorative member 34 (see FIG. 8 described later) for decorative purposes. The decorative member 34 is attached to the right end surfaces of the holding plate 32 and the front surface plate 33 by using an adhesive.
Similarly, the right end faces of the rear holding plate 32 and the front plate 33 are also decorated with a decorative member 34. The left end face of the frame 30 and the left end faces of the front plates 33, 33 are also decorated.

As shown in Figures 1 and 2, the right-side vertical frame 3 has a structure that is the same as the left-side vertical frame 3, but the center portions of the left edges of the retaining plate 32 and the front plate 33 of the right-side vertical frame 3 are missing.

As shown in Fig. 1, the upper ends of the vertical frames 3, 3 are connected to each other by a connector 12. The connector 12 is a metal fitting extending left and right. The connector 12 is fitted into an insertion groove 35 (see Fig. 3) provided from the upper end surface of the frame body 30 of each vertical frame 3 to the upper end surfaces of the retaining plates 32, 32. Both left and right ends of the connector 12 are fixed to the frame bodies 30, 30 of the vertical frames 3, 3 with screws. The upper end of the mirror plate 2 is inserted into an insertion groove (not shown) provided in the connector 12. The upper end of the mirror plate 2 may be held by the connector 12.
Similarly, the lower ends of the vertical frames 3, 3 are also connected to each other by connectors 12.

The left-right position of the rightmost end of the left vertical frame 3 is approximately equal to the left-right position of the leftmost end of the right vertical frame 3.
In a front view of the plate-shaped building material 1, the contour line of the right side of the left vertical frame 3 has a straight line extending vertically and curved lines continuing to both ends of the straight line. This curved line corresponds to the missing portion of the surface panel 33 (and the retaining plate 32) in the left vertical frame 3. The contour line of the left side of the right vertical frame 3 has two straight lines extending vertically and aligned one above the other, and arcs continuing between the two straight lines. This arc corresponds to the missing portion of the surface panel 33 (and the retaining plate 32) in the right vertical frame 3.

The straight line of the left vertical frame 3 and the two straight lines of the right vertical frame 3 are lined up one above the other with the straight line of the left vertical frame 3 in the center, and appear to be a straight line in the vertical direction. The two curved lines of the left vertical frame 3 and the arc of the right vertical frame 3 are lined up with the arc of the right vertical frame 3 in the center, and appear to be wavy left and right around the aforementioned straight line in the vertical direction.

The mirror panel 2 is exposed in the area surrounded by the outline of the right side of the left vertical frame 3, the outline of the left side of the right vertical frame 3, and the two upper and lower connectors 12, 12. The exposed portion of the mirror panel 2 is non-rectangular.

At first glance, the head panel 2 appears to be divided into three sections lined up one above the other. The top section is bounded by the curve of the left vertical frame 3, the straight line of the right vertical frame 3, and the upper connector 12. Similarly, the bottom section is bounded by the curve of the left vertical frame 3, the straight line of the right vertical frame 3, and the lower connector 12. The center section is bounded by the straight line of the left vertical frame 3 and the circular arc of the right vertical frame 3.

The mirror panel 2 is rectangular, but the exposed portion of the mirror panel 2 appears to be divided into multiple parts, each of which is non-rectangular, improving the design of the plate-shaped building material 1.

4 to 9 are explanatory diagrams of a manufacturing method for the plate-shaped building material 1. Fig. 10 is a cross-sectional view taken along line XX in Fig. 9.
As shown in FIG. 4, the manufacturer prepares the frame 30, the holding plates 320, 320 to be used as the holding plates 32, 32, and the spacer 5.
Each of the holding plates 320 is a rectangular plate that is long in one direction.
The spacer 5 is a rectangular plate that is long in one direction. The thickness of the spacer 5 is equal to the thickness of the end plate 2. The length of the spacer 5 is equal to the length of the retaining plate 320. The width of the spacer 5 is shorter than the width of the retaining plate 320 by the protruding length of the convex portion 311 of the vertical frame 31 (see FIG. 5).

The frame body 30 is formed by assembling a vertical frame 31, which has a protrusion 311 provided in advance, with vertical frames 301 and horizontal frames 302, 302 into a rectangular frame shape, and attaching horizontal bars 303, 303, ... to the assembled rectangular frame (see Figure 3).

As shown in FIG. 5, the manufacturer fixes the holding plates 320, 320 to the frame 30, for example, using a workbench 6. In this case, the manufacturer faces both sides of the holding plates 320, 320 and the spacer 5 up and down, and stacks one holding plate 320, the spacer 5, and the other holding plate 320 in that order on the top surface of the workbench 6. At this time, the manufacturer adjusts the positions of the holding plates 320, 320 and the spacer 5 so that their end faces in the length direction are flush with each other, and so that their end faces in the width direction are flush with each other.

This creates a gap surrounded by one of the long sides of each of the retaining plates 320 and the other end face in the width direction of the spacer 5. The manufacturer inserts the convex portion 311 of the vertical frame 31 into the gap so that the convex portion 311 faces the other end face in the width direction of the spacer 5, and brings the side surface on which the convex portion 311 of the vertical frame 31 is provided into contact with the end face of each of the retaining plates 320. The top surface of the frame body 30 and the top surface of the upper retaining plate 320 become flush with each other.

As a result of the above, the spacer 5 is sandwiched between the first surfaces of the holding plates 320, 320, and the convex portion 311 of the vertical frame 31 is sandwiched between the first surfaces of the holding plates 320, 320 and between the first sides of the holding plates 320, 320.
In addition, the manufacturer may place one of the holding plates 320 on the upper surface of the workbench 6, then place the convex portion 311 of the vertical frame 31 and the spacer 5 on the upper surface of one of the holding plates 320, and further place the other holding plate 320 on the upper surfaces of the convex portion 311 of the vertical frame 31 and the spacer 5.

Next, the manufacturer tackers the upper retaining plate 320 and the vertical frame 31 together using the fixing members 4. At this time, the manufacturer hammers the fixing members 4 into the retaining plate 320 and the vertical frame 31 from above (from the upper surface side of the retaining plate 320). The manufacturer hammers the multiple fixing members 4, 4, ... into the vertical frame 31 at appropriate intervals in the longitudinal direction of the vertical frame 31.
Since the convex portion 311 and the spacer 5 are sandwiched between the retaining plates 320, 320, even if an external force is applied when fastening with a tacker, the separation distance between the retaining plates 320, 320 is maintained, and the upper surface of the frame body 30 and the upper surface of the upper retaining plate 320 are kept flush with each other.

Furthermore, the manufacturer turns the frame body 30, the holding plates 320, 320, and the spacer 5 upside down. After that, the manufacturer uses the fixing members 4 (shown by two-dot chain lines in FIG. 5 ) to tack together the holding plate 320, which is on the upper side after the inversion, and the vertical frame 31, in the same manner as in the case of the holding plate 320, which was on the upper side before the inversion.
As a result of the above, the holding plates 320, 320 are fixed to the vertical frame 31 of the frame body 30.

As shown in FIG. 6, the manufacturer prepares surface plates 33, 33 and surface plates 330, 330 to be made.
Each surface plate 330 is a rectangular plate that is long in one direction. The length of the surface plate 330 is equal to the length of the holding plate 320. The width of the surface plate 330 is equal to the sum of the width of the holding plate 320 and the width of the frame 30.
The manufacturer applies adhesive from the top surface of the frame body 30 to the top surface of the upper holding plate 320. Next, the manufacturer turns both sides of one of the surface plates 330 up and down. The manufacturer covers the entire frame body 30 and the upper holding plate 320 from above with the surface plate 330, and attaches the bottom surface of the surface plate 330 to the top surface of the frame body 30 and the top surface of the upper holding plate 320.

Even if an external force is applied when bonding the surface plate 330, the distance between the holding plates 320, 320 is maintained due to the presence of the convex portion 311 and the spacer 5, and the top surface of the frame 30 and the top surface of the upper holding plate 320 are kept flush with each other.
Furthermore, the manufacturer inverts the frame body 30, the retaining plates 320, 320, the surface plate 330, and the spacer 5 upside down, and then, in the same manner as for one surface plate 330, attaches the other surface plate 330 (shown by a dotted line in Figure 6) to the retaining plate 320 and frame body 30 that are now on the upper side after inversion.

In this manner, a work-in-progress 360 is formed in which the surface plates 330, 330 are bonded to the frame 30 and the holding plates 320, 320 (see FIG. 7).
The manufacturer prepares a work-in-progress 360 to be completed as the left vertical frame 3, and a work-in-progress 360 to be completed as the right vertical frame 3. The configuration of the work-in-progress 360 to be completed as the left vertical frame 3 and the configuration of the work-in-progress 360 to be completed as the right vertical frame 3 are identical to each other.

As shown in FIG. 7, for each work-in-progress 360, the manufacturer cuts one long side of the retaining plates 320, 320 together with the surface plates 330, 330 and spacer 5 into a predetermined shape. Here, the long side to be cut is the second side, which is the long side farther from the frame body 30 (the long side not sandwiched by the convex portion 311 of the vertical frame 31). By cutting, parts of the retaining plates 320, 320, the surface plates 330, 330, and the spacer 5 are each removed. In FIG. 7, the parts to be removed by cutting are indicated by hatching.

Even if an external force is applied during cutting of the work-in-progress 360, the separation distance between the holding plates 320, 320 is maintained due to the presence of the convex portion 311 and the spacer 5. This prevents, for example, the holding plate 320 from bending during cutting, which could result in a deterioration in the cutting accuracy of the work-in-progress 360, or the holding plate 320 from falling off the frame 30.

After completing the cutting process of the work-in-progress 360, the manufacturer forms the vertical frame 3 by decorating the end faces using decorative members 34, 34 and forming fitting grooves 35, 35, as shown in FIG. 8.

As shown in FIGS. 9 and 10, the manufacturer prepares a head plate 2.
The manufacturer removes the spacer 5 from between the retaining plates 32, 32 of the vertical frame 3. By removing the spacer 5, a gap 321 is formed in the area surrounded by the protruding portion 311 of the vertical frame 31 and the retaining plates 32, 32.

The manufacturer then injects adhesive into the cavity 321 .
Furthermore, the manufacturer faces the end face of one long side (one side) of the mirror plate 2 toward the convex portion 311 and inserts the mirror plate 2 into the gap 321 until the end face of the mirror plate 2 abuts the convex portion 311. The adhesive injected into the gap 321 is interposed between the retaining plates 32, 32 and the mirror plate 2 as the mirror plate 2 is inserted into the gap 321. As a result, the adhesive force of the adhesive can be utilized to securely hold the mirror plate 2 between the retaining plates 32, 32.

After the stiles 3,3 hold the end panel 2, the manufacturer connects the stiles 3,3 to each other by fitting the connectors 12,12 into the fitting grooves 35,35 and screwing them to the stiles 3,3 (see FIG. 1).
At a construction site where the plate-shaped building material 1 is attached to a wall, the gripping portions 11, 11 are attached to the left vertical frame 3, and a hinge is attached to the right vertical frame 3.

According to the above-described manufacturing method of the plate-shaped building material 1, the fixing members 4 are driven downward from above the upper retaining plate 320. Therefore, the width dimension of the retaining plate 32 is not limited by the dimension of the fixing members 4. This improves the degree of freedom in designing the range in which the retaining plates 32, 32 hold the mirror plate 2. As a result, it is possible to improve the degree of freedom in the shape of the portion of the mirror plate 2 exposed from the retaining plates 32, 32.
The surface plates 33, 33 cover the frame body 30, the holding plates 32, 32, and the multiple fixing members 4, 4, ... from both the front and rear. Therefore, the boundary portion between the frame body 30 and the holding plates 32 is also hidden by the surface plate 33.
As a result of the above, the design of the plate-shaped building material 1 can be improved.

The frame body 30 including the vertical frame 31 and the holding plates 320, 320 and the mirror plate 2 (or the holding plates 32, 32 and the mirror plate 2) are adjacent to each other in a groove-like configuration, so that the components are prevented from shifting relative to each other in the front-to-rear direction during the manufacturing process of the plate-shaped building material 1.

Rectangular head plates 2 and retaining plates 320 are more readily available and easier to handle than non-rectangular ones.
Furthermore, the retaining plates 32, 32 and the surface plates 33, 33 are cut after the frame body 30, the retaining plates 32, 32, and the surface plates 33, 33 are fixed to each other. This improves the accuracy of the shape of the vertical frame 3 compared to when the frame body 30, the retaining plates 32, 32, and the surface plates 33, 33 are fixed to each other after the retaining plates 320, 320 and the surface plates 330, 330 are each cut.

Although the left and right vertical frames 3, 3 have different shapes, they can be manufactured from work-in-progress 360, 360 having the same configuration.
There is a high degree of freedom in cutting the holding plates 320, 320 and the surface plates 330, 330. Therefore, by preparing a plurality of work-in-progress 360, 360, ... and cutting each work-in-progress 360 into a different shape, a wide variety of vertical frames 3, 3, ... can be obtained. As a result, a wide variety of plate-shaped building materials 1, 1, ... can be obtained from one type of work-in-progress 360, 360, ...

It should be noted that the plate-shaped building material 1 is not limited to a hinged door, but may also be configured as, for example, a sliding door, a partition wall, or a sleeve wall panel.
The plate-shaped building material 1 is not limited to a two-sided frame door with vertical frames 3, 3. For example, the plate-shaped building material 1 may be a frame door with two horizontal frames. Here, the two horizontal frames are configured as if the vertical frames 3, 3 were turned over by 90 degrees. The plate-shaped building material 1 may be configured with only one vertical frame 3. The plate-shaped building material 1 may be a four-sided frame door.

The convex portion 311 is not limited to being provided over the entire length of the vertical frame 31. For example, a plurality of convex portions 311 may be arranged side by side in the longitudinal direction of the vertical frame 31.
The fixing member 4 is not limited to a staple for a tacker. For example, the fixing member 4 may be a screw, and the holding plate 320 may be screwed to the protruding portion 311 of the vertical frame 31. Alternatively, the fixing member 4 may be a nail, and may be driven obliquely from the holding plate 320 toward the vertical frame 31.

The configuration is not limited to one spacer 5 being sandwiched between the holding plates 320, 320. A plurality of spacers 5, 5, ... arranged along one surface of the holding plate 320 may be sandwiched between the holding plates 320, 320.

The vertical frame 31 and the retaining plate 32 may each be made of a material (e.g., wood) into which the fixing member 4 can be driven.
The holding plate 320, the surface plate 330, and the spacer 5 may be made of a material that can be cut (e.g., wood). However, the spacer 5 must be made of a material that is rigid enough to resist and maintain the separation distance between the holding plates 32, 32 against an external force that would shorten the separation distance. Furthermore, the spacer 5 is preferably made of a disposable, inexpensive material.

The number of end panels 2 included in the plate-shaped building material 1 is not limited to one.
FIG. 11 is a cross-sectional view of a plate-shaped building material 1 having two end panels 2, 2.
The plate-like building material 1 further includes a vertical frame 3 between the left and right vertical frames 3, 3. The central vertical frame 3 includes a pair of supporting plates 32, 32 facing each other in the front and rear on both the left and right sides.
The mirror panels 2, 2 are lined up side by side. The left side of the left mirror panel 2 is held by the left vertical frame 3, and the right side of the right mirror panel 2 is held by the right vertical frame 3. The right side of the left mirror panel 2 and the left side of the right mirror panel 2 are held by the central vertical frame 3.

The embodiments disclosed herein are illustrative in all respects and should not be considered limiting. The scope of the present invention is intended to include not only the above-mentioned meaning, but also the meaning equivalent to the claims and all modifications within the scope of the claims.

1 Plate-shaped building material 2 Mirror plate 3 Vertical frame (holding member)
31 Vertical frame (core material)
311: Convex portion 32: Holding plate 320: Holding plate 33: Surface plate 330: Surface plate 4: Fixing member 5: Spacer

Claims (4)

A rectangular mirror plate;
A plate-shaped building material comprising: a holding member that holds one side of the mirror plate,
The holding member is
A frame body having a protrusion on a peripheral surface thereof facing an end surface of the one side portion and including a straight rod-shaped core material along the end surface;
two holding plates , the protrusion and the one side portion being sandwiched between the respective one surfaces thereof, and fixed to the core material by a plurality of fixing members driven into the respective other surfaces thereof;
and two surface panels attached to the frame body and the two retaining plates so as to cover the frame body , the two retaining plates, and the fixing member from the other side of each of them. A rectangular mirror plate;
a frame including a straight rod-shaped core material having a protrusion protruding from a peripheral surface in a direction perpendicular to the length direction, the protrusion having a length in a direction perpendicular to both the protruding direction and the length direction being equal to the thickness of the end plate ;
Two retaining plates;
Two surface panels,
a plate-shaped spacer having a thickness equal to the thickness of the end plate;
The two holding plates are fixed to the core material by sandwiching the protrusion and the spacer between one surface of each of the two holding plates and driving a fixing member into the two holding plates and the core material from the other surface side of each of the two holding plates;
Attaching the two surface plates to the frame body and the two holding plates so as to cover the frame body , the two holding plates, and the fixing member from the other side of each of the two holding plates with the two surface plates;
Remove the spacer from between the two retaining plates;
A method for manufacturing a plate-shaped building material, characterized in that the end face of one side of the mirror plate is inserted between the two retaining plates with the end face facing the convex portion, thereby sandwiching the one side between the two retaining plates. Providing two rectangular retaining plates;
When the two holding plates are fixed to the core material, the protrusion is sandwiched between first side portions of the two holding plates,
A manufacturing method for a plate-shaped building material as described in claim 2, characterized in that before removing the spacer from between the two retaining plates, the second edge portions opposite the first edge portions of each of the two retaining plates are cut into a predetermined shape together with the two surface panels and the spacer. The method for manufacturing a plate-shaped building material according to claim 2 or 3, characterized in that adhesive is injected between the two holding plates before the end plate is inserted between the two holding plates.

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