JPH06221060A - Curved door and manufacture thereof - Google Patents

Abstract

PURPOSE:To reduce the cost of material and weight of a web core and make it difficult to deform according to the lapse of time by using the web core which is free to bend and deform. CONSTITUTION:A pair of vertical blocks 25, an upper block 27, and a lower block 26 are positioned at four sides of a web core to form a core assembly 2. Also surface plates 4 and 5 in which the surface faced on the core assembly side is coated with adhesive agent are positioned on both upper and lower sides of the core assembly 2 to put the surface plates on the core assembly. Then the surface plates and core assembly are heated, pressed, and formed by holding them between the curved projecting surface of a male-formed die 6 and the curved projecting surface of a female-forming die 7 to form the surface plates and core assembly in curved shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curved door curved along a cylindrical surface and a manufacturing method thereof.

[0002]

2. Description of the Related Art Doors for entrances and exits of houses or doors for furniture are usually formed in a flat surface, but depending on the purpose of use, for example, a sideboard door or the like may be a curved door. . As a conventional method for manufacturing such a curved door, (a) as shown in FIG. 6, a wood having a relatively thick rectangular cross section capable of covering a thickness t from the lower surface on both sides of the curved door to be manufactured to the central upper surface. a or a wood b of trapezoidal cross section is prepared, and unnecessary parts are cut from those plates so as to have a curved cross section, or (b) an adhesive is applied to the surface of a plurality of thin laminated veneer. Then, a method is known in which they are superposed on each other, and the superposed one is sandwiched between a male molding die having a curved convex surface and a female molding die having a curved concave surface to perform heat compression molding.

However, in the former case (a), since a large number of parts are to be cut and processed, the wood is wasted, and the work is time-consuming and the cost is high, and the door is heavy. There is a drawback. The latter (b)
In this case, not only is the cost high and the door heavy due to the large amount of plate material, adhesive, etc. used, but also the door tends to return to a flat state over time.

[0004]

The problem to be solved and used by the present invention is that the use of the web core allows the web core to be freely curved and deformed, so that the material cost is low, the weight is low, and the time elapses. It is an object of the present invention to provide a curved door that is hard to be deformed in accordance with the above and a manufacturing method thereof.

[0005]

According to one aspect of the present invention, there is provided a curved door in which a surface plate is arranged on each of upper and lower sides of a core assembly which is formed by arranging a pair of vertical frames, an upper frame and a lower frame on four circumferences of a web core. And superimpose them on top of each other, and the superposed surface plate and core assembly are joined with an adhesive and sandwiched between a male molding die having a curved convex surface and a female molding die having a curved concave surface to form a curved shape by heating and pressure welding. Formed and configured. A method for manufacturing a curved door according to another invention of the present application is to form a core assembly by arranging a pair of vertical frames, an upper frame and a lower frame around the four circumferences of a web core, and forming the core assembly on the upper and lower sides of the core assembly. A surface plate coated with an adhesive is placed on the surface facing the body side, the surface plate and the core assembly are superposed, and the superposed surface plate and core assembly are formed into a curved convex surface of a male molding die and a female molding die. It is constructed such that it is sandwiched by a curved concave surface and is heat-pressed to form the surface plate and the core assembly into a curved shape.

[0006]

In the curved door having the above structure, the web core is used for the core, so that the weight is reduced. Further, since the web core is inexpensive, has flexibility in bending, and can be easily processed, the cost of the product can be reduced. Furthermore, since the web core exerts almost no restoring force, there is no problem that the door once processed into a curved shape returns to a flat shape.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. Prior to manufacturing a curved door by the manufacturing method of the present invention, first, a desired width W and length L and a desired thickness T determined by the size of the door to be manufactured, as shown in FIG. The core assembly 2 is prepared. In this embodiment, the core assembly 2 includes a thin first core member 21 having a width matching the thickness T, a thin second core member 22 having substantially the same width and bent into a V shape, and a V-shaped tip. And a third core member 23 in which V is recessed as shown in FIG. 1 and both ends of the core members 22 and 23 are attached to the first core member 21 to form a web core 20. Vertical stiles 25 on both left and right sides (in FIG. 1) of the
In (), a lower frame 26 and an upper frame 27 are arranged. In this case, the core materials 21 arranged at both ends of the web core 20 are joined to the vertical frame 25 in advance. The upper and lower frames do not necessarily have to be joined vertically or to the web core.

The core materials 21, 22, 23 are made of a known web material such as paper, cardboard, resin-processed paper.
Further, although it is cheaper to make the vertical frame 25 and the upper and lower frames 27 and 26 with a processing material such as fiberboard or particle board, ordinary wood may be used. In any case, a plurality of slits extending at right angles to the longitudinal direction of the upper and lower frames (the surface that becomes the inner peripheral side of the arc when curved) to facilitate bending are formed on one surface of the upper and lower frames. 26a and 2
7a are formed at predetermined intervals along the longitudinal direction. In addition, a slit 25a extending along the longitudinal direction may be formed on one surface of the vertical frame 25 to facilitate bending. The core material may have a width several times larger than the thickness T of the web core 20 to form a thicker web core, and then cut to a desired thickness T. Further, the web core may be a so-called honeycomb core formed by bending and joining a web material into a honeycomb shape, and is not necessarily limited to the shape shown in FIG. Therefore, in the present application, the web core is a concept including a so-called honeycomb core.

On the other hand, the core assembly 2 as described above is prepared, and a pair of surface plates 4 and 5 forming the surface of the door are also prepared. This face plate may be a bare wood plate or plywood. Further, when the surface of the outside of the door is processed to have irregularities, such processing is performed in advance.

After applying an adhesive to the surface of the surface plates 4 and 5 facing the core assembly 2 side, the surface plates and the core assembly are superposed as shown in FIG.
It is placed between the curved convex surface 6a and the curved concave surface 7a of the female molding die 7. Then, as shown in FIG. 4, the two molding dies 6 and 7 are brought close to each other to press the surface plate and the core assembly with a desired pressure, and the curved convex surfaces 6a and the curved concave surfaces 7a act so that the surface plates 4 and 5 are not pressed. The core assembly 2 and the core assembly 2 are formed into a curved shape, and they are bonded with an adhesive. In this case, a thermosetting adhesive is used as the adhesive applied to the surface of the surface plate, and the surface plate and the core assembly are pressed by a pair of molding dies and heated by applying high frequency to cure the adhesive. However, the curing speed of the adhesive is high, and therefore the door is manufactured efficiently, but other adhesives may be used. While the front plate and the core assembly are pressed by both molds, they are cooled, and then the molds are separated from each other to take out the curved door 1 formed into a curved shape as shown in FIG. Since the molding die and the device for applying a high frequency to the core assembly and the surface plate during molding may have a known structure and function, detailed description thereof will be omitted.

The vapor generated from the adhesive in the course of the above-mentioned curing of the adhesive and the molding process of the door fills the space defined by the core assembly 2 between the pair of face plates 4 and 5, It is possible to escape to the outside through the slits 26a and 27a formed in the upper and lower frames 26 and 27, and it is possible to prevent the surface plate from unnaturally bulging outward by steam. Further, when the heated door is cooled in the process of the steam process, the air in the space is also cooled and tends to have a negative pressure, but since the outside air flows into the space through the slit, it does not become a negative pressure. .

In the above embodiment, the curved door is arranged in the width direction,
That is, the case of bending along the upper and lower frames has been described, but by replacing the vertical frame of the above embodiment with the upper and lower frames and by replacing the upper and lower frames with the vertical frame, in the longitudinal direction, that is, with the vertical frame. It is also possible to bend in the direction along the frame. Further, in the above-mentioned embodiment, the case where the surface plate 4 is processed to have irregularities is shown. However, when a flat surface plate is used,
The shape of the curved concave surface 7a of the female molding die 7 is also adapted to it.

[0013]

According to the present invention, the following effects can be obtained. (1) Since the web core is inserted between both surface plates and curved, the bending is easy and the manufacturing is simple, and the manufacturing cost of the curved door can be reduced. (2) Since the web core itself is inexpensive, the cost of the curved door can be reduced together with the reduction of the manufacturing cost. (3) Further, since the web core is lightweight, the curved door can be made lightweight. (4) Since the portion to be cut is extremely smaller than that in the conventional manufacturing method (a), it is possible to prevent waste of expensive and precious natural wood. (5) Since the bendability of the web core is used, there is little possibility that the door will be restored to a flat shape as in the case of the above-mentioned conventional manufacturing method (b).

[Brief description of drawings]

FIG. 1 is a perspective view of a core assembly used in a curved door of the present invention.

2 is an end view showing the core assembly and face plate of FIG. 1. FIG.

FIG. 3 is an end view showing a state in which the core assembly and the surface plate of FIG. 1 are superposed on each other.

FIG. 4 is an end view showing a state in which a core assembly and a face plate are molded into a curve by a male and a female molding dies.

FIG. 5 is a perspective view of a curved door formed by the method of the present invention.

FIG. 6 is a diagram showing a conventional method for manufacturing a curved door.

[Explanation of symbols]

 1 Curved Door 2 Core Assembly 4, 5 Surface Plate 6 Male Mold 7 Female Mold 21 Vertical Frame 22, 23 Horizontal Frame

Claims (2)

[Claims] 1. A surface assembly is arranged on the upper and lower sides of a core assembly having a pair of vertical frames, an upper frame and a lower frame arranged around the four circumferences of a web core, and these are superposed, and the superposed surface plate and core assembly. A curved door, characterized in that the three-dimensional body is joined with an adhesive and sandwiched between a male molding die having a curved convex surface and a female molding die having a curved concave surface to form a curved shape by heat-pressure contact molding. 2. A core assembly is formed by arranging a pair of vertical frames, an upper frame and a lower frame around the four circumferences of a web core, and an adhesive is provided on the upper and lower sides of the core assembly, the surface facing the core assembly side. A surface plate coated with is placed, and the surface plate and the core assembly are superposed, and the superposed surface plate and core assembly are sandwiched between the curved convex surface of the male molding die and the curved concave surface of the female molding die and heated and pressure welded. A method for manufacturing a curved door, which comprises molding and thereby forming the surface plate and the core assembly in a curved shape.