JP2004060378A

JP2004060378A - Door panel and method of manufacturing the same

Info

Publication number: JP2004060378A
Application number: JP2002223006A
Authority: JP
Inventors: Takanobu Nomura; 野村　孝伸
Original assignee: Daiken Trade and Industry Co Ltd
Current assignee: Daiken Trade and Industry Co Ltd
Priority date: 2002-07-31
Filing date: 2002-07-31
Publication date: 2004-02-26
Anticipated expiration: 2022-07-31
Also published as: JP3955244B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a door panel to which a decoration panel and a decoration plate can be firmly connected without deterioration of their appearance. <P>SOLUTION: The door panel is provided with right and left decoration panels (1) formed of a surface decoration member (4) and a core material (3), and a decoration plate (2). The right and left both side ends (2a) of the decoration plate (2) are connected in the fitting state into inside side end face (3a) of the core material (3) of the decoration panel (1) and fixed so as to insert the connection part by a fixing member (5) such as a dowel and further the exposed part of the fixing member exposed on the surface of the core material is covered with a surface decoration member. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、建築物のドア、引き戸、或いはクローク収納等の収納体の扉に用いるに好適な戸パネルおよびその製造方法に関する。
【０００２】
【従来の技術】
従来から、建築物のドア、引き戸、或いはクローク収納など収納体の扉には、框部など左右の化粧パネルと該左右の化粧パネルの間に配され、該化粧パネルと一体に接合されて戸パネルを構成する鏡板やガラス板などの装飾板とで構成されているものが良く知られている。
【０００３】
このような化粧パネルと装飾板を接合固定するには、例えば化粧パネルの内側側端面に嵌合凹部を形成しておき、この嵌合凹部に装飾板の左右の側端部を嵌入して接着剤で固定する方法がある。また、表面からビスなどで化粧パネルと装飾板をビス止めする方法もあるが、この場合にはビス頭が表面に露出して装飾性を損なうので化粧キャップでカバーされる。
【０００４】
【発明が解決しようとする課題】
しかしながら、このような戸パネルは、接着だけでは化粧パネルと装飾板とが十分に固定されず、装飾板にガタツキなどを生じることがあり、特に木質材からなる化粧パネルにガラスや樹脂板など異種材料からなる装飾板を接着剤で固定しようとする場合には、このような問題が発生し易かった。また、戸パネルのデザイン性を高めるため、装飾板を上下の框がない状態に上から下まで通しで接合固定しようとする場合には、上下で支えるものがなく側面だけで接合固定するため、更に上記のガタツキなどの接合不良を生じる危惧が高くなる。また、化粧パネルの表面からビス等固定具で固定する場合には、化粧キャップでカバーしても違和感のある外観となってその装飾性を減じるものであった。
【０００５】
本発明は、かかる従来の欠点に鑑みなされたもので、表面の装飾性を損なわずに化粧パネルと装飾板とを生産性良く強固に固定することができ、更には装飾板が化粧パネルに上から下まで通しで固定されるような多様なデザインの戸パネルであっても、両者を強固に固定でき、また生産性良く製造できる戸パネルおよびその製造方法を提供することを目的とする。
【０００６】
【課題を解決するための手段】
上記の目的を達成するため、請求項１の発明に係る戸パネルは、表面化粧材と芯材とからなる左右の化粧パネルと、上記芯材より薄い厚さの装飾板とを備えた戸パネルであり、該装飾板の左右両側端部が化粧パネルの芯材の内側側端面に嵌入状態に接合されてなるとともに、該芯材の内側側端部の一方側表面から他方側表面に向けて上記装飾板の左右側端部を貫通する固定部材により化粧パネルの芯材と装飾板とが一体に固定されてなり、更に芯材表面に露出する上記固定部材の露出部が表面化粧材により被覆されてなる構成とした。
【０００７】
これによれば、化粧パネルの芯材と装飾板とを嵌入状態に接合し、更に固定部材によって両者貫通状に固定するものであるので、非常に強固に固定された戸パネルを得ることができ、多様なデザインの戸パネルにも適用できる。そして、固定部材が芯材の表面に露出する露出部が表面化粧材によって被覆されているので、固定部材の露出部を隠蔽する化粧キャップは不要となり、装飾性に優れた戸パネルを得ることができる。
【０００８】
請求項２の発明に係る戸パネルは、請求項１の発明において、表面化粧材にＶカット化粧板を用いた構成とした。これによれば、厚みのあるＶカット化粧材によって芯材表面に露出した固定部材を一層良好に被覆することができるとともに、芯材の角部にＶカット部をあてがい、表面に沿うように折り曲げて表面化粧材を芯材に固定できるので、生産性良く製造することができる。
【０００９】
請求項３の発明に係る戸パネルは、請求項１又は２の発明において、装飾板としてポリカーボネート樹脂板を用いる構成とした。このことにより、戸パネルに採光性・光透過性を付与できることは勿論、ガラスやスリガラスに較べて軽量で加工や固定部材による固定がし易く、製造工程での破損も少なくすることができる。
【００１０】
請求項４の発明に係る戸パネルの製造方法は、表面化粧材と芯材とで構成される左右の化粧パネルの芯材の内側側端面に、該芯材より薄い装飾板の両側端部を嵌入状態に接合する工程と、該接合された芯材の内側側端部と装飾板の両側端部とを、該芯材の一方側表面から他方側表面に向けて上記装飾板の左右側端部が貫通するように固定部材で固定する工程と、装飾板を固定した芯材の表面を固定部材の露出部が被覆されるように表面化粧材で被覆する工程とを順次備えてなる構成とした。これによれば、化粧パネルと装飾板とを、化粧パネル表面の化粧性を損なうことなく、強固に接合固定された戸パネルを非常に良好に製造することができる。
【００１１】
請求項５の発明に係る戸パネルの製造方法は、請求項４の発明において、内側側端部の芯材が複数枚の板材で形成されており、この板材間に装飾板の両側端部を挟み込んで接着することにより芯材の内側側端面に装飾板の両側端部を嵌入状態に接合してなる構成とした。これによれば、装飾板の両側端部を芯材の内側側端面に確実に接合保持でき、その後の加工工程における加工作業を容易にし、戸パネルの生産性を一層向上させることができる。
【００１２】
請求項６の発明に係る戸パネルの製造方法は、請求項４又は５の発明において、表面化粧材としてＶカット化粧板を用いた構成とした。これによれば、芯材の角部にＶカット部をあてがい、芯材表面に沿うように折り曲げて表面化粧材を芯材に固定できるので、芯材に装飾板を固定した後においても、表面化粧材を芯材に接着剤などにより良好に固定することができる。また、Ｖカット化粧板は基板の表面に化粧シートを貼着して形成されているので、芯材表面に露出した固定部材の露出部を確実に被覆することができる。
【００１３】
請求項７の発明に係る戸パネルの製造方法は、装飾板としてポリカーボネート樹脂板を用いる構成とした。このことにより、戸パネルに採光性・透過性を付与することができ、またガラスやスリガラスに較べ軽量で加工し易く、固定部材による固定が容易な上、製造工程での破損も少ないので戸パネルの生産性を一層向上させることができる。
【００１４】
【発明の実施の形態】
図１〜図３は、本発明の実施形態に係る戸パネル（Ａ）の説明図である。この戸パネル（Ａ）は、左右に配された化粧パネル（１）（１）と中央部に配されたすりガラス調のポリカーボネート樹脂板製装飾板（２）とから構成されており、化粧パネル（１）（１）および装飾板（２）が、図３に示すようにそれぞれ上から下まで通しの状態になるシンプルなデザインに形成されている。
【００１５】
化粧パネル（１）（１）は、図１及び図２に示すように内側及び外側の縦桟材（ａ）（３ｂ）と、この縦桟材（３ａ）（３ｂ）の間に設けられた複数（図では８本）の横桟材（３ｃ）と、上下部及びノブ取付部に設けられた補強板材（３ｄ）とで形成される骨組み中空状の芯材（３）と、この芯材（３）の周囲を覆うＶカット化粧板製表面化粧材（４）とで形成されている。
【００１６】
芯材（３）の内側縦桟材（３ａ）は、装飾板（２）の両側端部（２ａ）を囲うように配された３枚の板材（３ａ１）、（３ａ２）、（３ａ３）で形成されており、この３枚の板材（３ａ１）、（３ａ２）、（３ａ３）で装飾板（２）の両側端部（２ａ）が嵌入状態に接着接合されている。そして、この芯材（３）の内側縦桟材（３ａ）と装飾板（２）の両側端部（２ａ）とが重なる部分において、芯材（３）の一方面から他方面に貫通する貫通孔が形成されており、この貫通孔にダボからなる固定部材（５）が打ち込まれて、芯材（３）と装飾板（２）とが強固に固定されている。
【００１７】
そして、前記したように芯材（３）の周囲がＶカット化粧板からなる表面化粧材（４）で被覆されているので、固定部材（５）であるダボやダボ孔が芯材（３）の表面に露出する露出部は、表面化粧材（４）によって確実に被覆されている。
【００１８】
ここにおいて、芯材（３）として前記骨組み中空状のものを用いると、戸パネルを軽量に形成できるという利点がある。しかし、これに限らず例えば、縦桟材（ａ）、（３ｂ）間の中空部にハニカム体を充填して強度や面圧縮強度を向上させたものや、繊維マット状物や樹脂発泡体からなる断熱材を充填して断熱性を向上させたものを用いることもできる。また、重くなるが、木材、合板、ＭＤＦ、集成材、或いはそれらの複合材などからなるソリッドな木質材を用いてもよい。
【００１９】
また、上記実施形態では、芯材（３）と装飾板（２）の両側端部（２ａ）との接合を、芯材（３）の内側の縦桟材（３ａ）を形成する３枚の板材（３ａ１）、（３ａ２）、（３ａ３）で嵌入状態に接着接合する例を示したが、これに限らず、例えば縦桟材（３ａ）の内側側端面にこの側端面に開口する凹部を形成し、この凹部に装飾板（２）の両側端部（２ａ）を挿入し嵌入状態に接合するようにしてもよい。また接合に際しては、接着剤を使用することが接合を確実にする上で好ましいが、嵌入だけで十分接合状態が保持できる場合には接着剤の使用は不要である。
【００２０】
さらに、上記実施形態では、固定部材（５）にダボを用いて芯材（３）の内側側端部と装飾板（２）の両側端部（２ａ）とを貫通状態に強固に固定する好適な例を示したが、これに限らず、例えば芯材（３）の一方面から他方面へ装飾板（２）の両側端部（２ａ）を少なくとも貫く半貫通状態に固定してもよい。ダボに限らず、ビスやネジを固定部材（５）として用い固定してもよい。
【００２１】
また、上記実施形態では、装飾板（２）としてポリカーボネート樹脂板を用いる例を示したが、このようなポリカーボネート樹脂板は、ガラスと同様採光性・透過性を装飾板（２）に付与できるとともに、ガラスに較べて軽くて強度や靭性があり、接着性や加工性が良く、また割れなどの損傷も生じ難いという利点があるので好適である。しかし、装飾板（２）としては、これに限らず例えば木質化粧板、ガラス、アクリル樹脂、スチレン樹脂等の透明・半透明樹脂板などを用いることもできる。
【００２２】
また、上記実施形態では、表面化粧材（４）としてＶカット化粧板を用いる例を示した。このＶカット化粧板は、図７に示すように合板、ＭＤＦ、火山性ガラス質複層板などからなる薄い基板の表面に合成樹脂化粧シート、突板などのシート状化粧材を貼着し、基板裏側からシート状化粧材に略至るＶ字状、円弧状などの所謂Ｖカット溝（７）を所定位置に切削により施したものであり、厚みがあるのでダボ孔やビス孔の窪みやダボやビス頭の若干の出っ張りや窪みがあっても、それらが戸パネル（Ａ）の表面に現出するのを確実に防ぐことができる。また、適度な強度を有しているので、芯材（３）が本実施形態のような骨組み中空状であっても、表面材として外力に対抗する十分な強度を備えており、好ましい。尚、芯材が前記ソリッドな木質材からなる場合など外力に対抗する十分な強度を全面に備えている場合には、表面化粧材（４）として合成樹脂化粧シートや突板などのシート状化粧材を用いることも可能である。
【００２３】
次に本願発明の戸パネル（Ａ）の製造方法に係る実施形態を図４〜図７に基づき説明する。図４において、先ず骨組み中空状の芯材（３）の内側側端部（３ａ）の端面に設けた凹部（６）に接着剤を塗布し、ポリカーボネート樹脂製の装飾板（２）の側端部（２ａ）を上記凹部（６）に嵌入して接着固定し、芯材（３）に装飾板（２）を嵌入状態に接合する。
【００２４】
次いで第５図に示すように、芯材（３）の内側側端部（３ａ）の一面側から装飾板（２）の側端部（２ａ）を貫いて他面側に貫通するように複数箇所ダボ孔（５ａ）を穿設し、このダボ孔（５ａ）にダボ（５）を埋め込むことにより芯材（３）に装飾板（２）を強固に固定する。
【００２５】
次いで、第６図に示すＶカット化粧板からなる表面化粧材（４）を、図７に示すように芯材（３）の周面に、Ｖカット部（７）が対応する芯材（３）の角部に当接するように接着剤を用いて接着固定することにより、本願発明にかかる戸パネル（Ａ）を生産性良く製造することができる。
【００２６】
ここにおいて、最初の芯材（３）に装飾板（２）を嵌入状態に接合する工程は、図７のａ、ｂに示すようにすることもできる。即ち、芯材（３）の内側縦桟材（３ａ）を３枚の板材（３ａ１）、（３ａ２）、（３ａ３）で構成し、装飾板（２）の両側端部（２ａ）を上下の板材（３ａ１）、（３ａ２）でサンドイッチし、空間を板材（３ａ３）で埋めて、接着剤により加圧、或いは加熱加圧して芯材（３）と装飾板（２）とを嵌入状態に接合するものである。この場合には、内側縦桟材（３ａ）に凹部（６）を形成する必要がなく、また装飾板（２）と芯材（３）とをプレスにより強固に接着することができるので、より好ましい。
【００２７】
【発明の効果】
以上説明した如く、請求項１の発明に係る戸パネルによると、装飾板の左右両側端部を化粧パネルの芯材の内側側端面に嵌入状態に接合し、この部分を固定部材により貫通状態に固定し、更に芯材表面に露出する固定部材の露出部を表面化粧材で覆うように構成しているので、芯材と装飾板とを非常に強固に固定することができるとともに、表面に化粧キャップなどを取り付ける必要がないので装飾性を減じることがない。そして、今まで装飾性を減じることなく強固に固定するのが難かしかった多様なデザインの戸パネルであっても生産性良く形成できるようになった。
【００２８】
また、請求項２の発明に係る戸パネルによると、表面化粧材としてＶカット化粧板を用いているので、厚みのあるＶカット化粧材によって芯材表面に露出した固定部材を一層良好確実に被覆することができるとともに、芯材の角部に予め位置決めされたＶカット部をあてがい、表面に沿うように折り曲げて表面化粧材を芯材に固定できるので、更に生産性良く製造することができる。
【００２９】
また、請求項３の発明に係る戸パネルによると、装飾板としてポリカーボネート樹脂板を用いているので、戸パネルに採光性・光透過性を付与することができるのは勿論のこと、ガラスやスリガラスに較べて軽量で加工や固定部材による固定がし易く、製造工程での破損も少なくすることができる。
【００３０】
また、請求項４の発明に係る戸パネルの製造方法によると、芯材の内側側端面に、装飾板の両側端部を嵌入状態に接合する工程と、この接合部分を固定部材により貫通状に固定する工程と、固定部材の露出部を含む芯材の周面を表面化粧材で被覆する工程とを順次備えているので、化粧パネルと装飾板とを化粧パネル表面の化粧性を損なうことなく、強固に接合固定された戸パネルを非常に良好に製造することができる。
【００３１】
また、請求項５の発明に係る戸パネルの製造方法によると、請求項４の発明において、内側側端部の芯材を複数枚の板材で形成し、この板材間に装飾板の両側端部を挟み込んで接着することにより芯材の内側側端面に装飾板の両側端部を嵌入状態に接合しているので、装飾板の両側端部を芯材の内側側端面に確実に接合保持でき、その後の加工工程における加工作業を容易にし、戸パネルの生産性を一層向上させることができる。
【００３２】
また、請求項６の発明に係る戸パネルの製造方法によると、請求項４又は５の発明において、表面化粧材としてＶカット化粧板を用いているので、芯材の角部に予め位置決めされたＶカット部をあてがい、芯材表面に沿うように折り曲げて表面化粧材を芯材に固定できるので、芯材に装飾板を固定した後においても、表面化粧材を芯材に接着剤などにより良好に固定することができる。また、Ｖカット化粧板は基材表面に化粧シートを貼着して形成されているので厚みがあり、芯材表面に露出した固定部材の露出部を確実に被覆することができる。
【００３３】
また、請求項６の発明に係る戸パネルの製造方法によると、請求項４乃至６の発明において、装飾板としてポリカーボネート樹脂板を用いているので、戸パネルに採光性・透過性を付与することができるのは勿論のこと、またガラスやスリガラスに較べ軽量で加工し易く、固定部材による固定が容易な上、製造工程での破損も少ないので戸パネルの生産性を一層向上させることができる。
【図面の簡単な説明】
【図１】本発明の実施形態である戸パネル（Ａ）の芯材と装飾板を接合した状態を示す説明図である。
【図２】本発明の実施形態である戸パネル（Ａ）の水平断面を示す説明図である。
【図３】本発明の実施形態である戸パネル（Ａ）の表面外観を示す説明図である。
【図４】本発明の実施形態である戸パネル（Ａ）の製造方法を示す説明図である。
【図５】本発明の実施形態である戸パネル（Ａ）の製造方法を示す説明図である。
【図６】本発明の実施形態である戸パネル（Ａ）の製造方法を示す説明図である。
【図７】本発明の実施形態である戸パネル（Ａ）の製造方法を示す説明図である。
【図８】本発明の実施形態である戸パネル（Ａ）の製造方法の変形例を示す説明図である。
【符号の説明】
（Ａ）　　戸パネル
（１）　　化粧パネル
（２）　　装飾板
（３）　　芯材
（４）　　表面化粧材
（５）　　ダボ[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a door panel suitable for use as a door of a building, a sliding door, or a door of a storage body such as a cloakroom, and a method of manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, doors of a storage body such as a building door, a sliding door, or a cloakroom are arranged between left and right decorative panels such as a frame portion and are integrally joined with the decorative panel. What is composed of a decorative plate such as a mirror plate or a glass plate constituting a panel is well known.
[0003]
In order to join and fix such a decorative panel and a decorative plate, for example, a fitting concave portion is formed on an inner side end surface of the decorative panel, and left and right side ends of the decorative plate are fitted into the fitting concave portion and adhered. There is a method of fixing with an agent. There is also a method of screwing the decorative panel and the decorative plate with screws from the surface, but in this case, the head of the screw is exposed on the surface to impair the decorativeness, so that it is covered with a decorative cap.
[0004]
[Problems to be solved by the invention]
However, in such a door panel, the decorative panel and the decorative panel are not sufficiently fixed only by bonding, and the decorative panel may be rattled. In particular, a decorative panel made of a wooden material is made of a different material such as glass or resin. When a decorative plate made of a material is to be fixed with an adhesive, such a problem is likely to occur. In addition, when trying to join and fix the decorative board from top to bottom without the upper and lower frames to enhance the design of the door panel, there is no support at the top and bottom, and the joint is fixed only at the side, Further, there is a high possibility that the above-mentioned loose connection or the like may occur. Further, when the decorative panel is fixed from the surface of the decorative panel with a fixing tool such as a screw, even if the decorative panel is covered with a decorative cap, the appearance becomes uncomfortable and the decorativeness is reduced.
[0005]
The present invention has been made in view of the conventional drawbacks, and enables the decorative panel and the decorative plate to be firmly fixed with good productivity without impairing the decorativeness of the surface. An object of the present invention is to provide a door panel and a method of manufacturing the door panel, which can be firmly fixed to each other even if the door panels are variously designed to be fixed from below to below and can be manufactured with high productivity.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, a door panel according to the invention of claim 1 includes a left and right decorative panel including a surface decorative material and a core material, and a decorative panel having a thickness smaller than the core material. The decorative plate has both left and right end portions joined to the inside end surface of the core of the decorative panel in a fitted state, and from the one surface to the other surface of the inside end of the core. The core material of the decorative panel and the decorative plate are integrally fixed by a fixing member penetrating the left and right ends of the decorative plate, and the exposed portion of the fixing member exposed on the core material surface is covered with a surface decorative material. The configuration was made.
[0007]
According to this, the core material of the decorative panel and the decorative plate are joined in a fitted state, and furthermore, both are fixed in a penetrating manner by the fixing member, so that a very firmly fixed door panel can be obtained. It can also be applied to door panels of various designs. Since the exposed portion where the fixing member is exposed on the surface of the core member is covered with the surface decorative material, a decorative cap for concealing the exposed portion of the fixing member is not required, and a door panel with excellent decorativeness can be obtained. it can.
[0008]
A door panel according to a second aspect of the present invention is the door panel according to the first aspect of the present invention, wherein a V-cut decorative panel is used as a surface decorative material. According to this, the fixing member exposed on the surface of the core material can be better covered with the thick V-cut decorative material, and the V-cut portion is applied to the corner of the core material and bent along the surface. As a result, the surface decorative material can be fixed to the core material, so that it can be manufactured with high productivity.
[0009]
A door panel according to a third aspect of the present invention is a door panel according to the first or second aspect of the invention, wherein a polycarbonate resin plate is used as a decorative plate. As a result, the door panel can be provided with daylighting and light-transmitting properties, as well as being lightweight and easily processed and fixed by a fixing member as compared with glass or ground glass, and can be less damaged in the manufacturing process.
[0010]
A door panel manufacturing method according to a fourth aspect of the present invention provides the door panel manufacturing method according to the fourth aspect, wherein the left and right ends of the decorative plate, which are thinner than the core, are provided on the inner end faces of the cores of the left and right decorative panels composed of the surface decorative material and the core. The step of joining in a fitted state, and the left and right ends of the decorative plate, with the inner end of the joined core and the both ends of the decorative plate facing from one surface to the other surface of the core. A step of fixing with a fixing member so that the portion penetrates, and a step of sequentially covering the surface of the core material to which the decorative plate is fixed with a surface decorative material such that the exposed portion of the fixing member is covered. did. According to this, a door panel in which the decorative panel and the decorative plate are firmly joined and fixed without impairing the decorativeness of the decorative panel surface can be manufactured very favorably.
[0011]
In the method of manufacturing a door panel according to a fifth aspect of the present invention, in the invention of the fourth aspect, the core material at the inner side end is formed of a plurality of plates, and the both ends of the decorative plate are provided between the plates. By sandwiching and bonding, both ends of the decorative plate are joined to the inner end surface of the core material in a fitted state. According to this, both end portions of the decorative plate can be reliably joined and held to the inner end surface of the core material, and the working operation in the subsequent working process can be facilitated, and the productivity of the door panel can be further improved.
[0012]
A method of manufacturing a door panel according to a sixth aspect of the invention is the door panel manufacturing method according to the fourth or fifth aspect, wherein a V-cut decorative board is used as a surface decorative material. According to this, the V-cut portion is applied to the corners of the core material, and the surface decorative material can be fixed to the core material by bending along the surface of the core material. The cosmetic material can be satisfactorily fixed to the core material with an adhesive or the like. Further, since the V-cut decorative board is formed by attaching a decorative sheet to the surface of the substrate, it is possible to reliably cover the exposed portion of the fixing member exposed on the surface of the core material.
[0013]
In the method for manufacturing a door panel according to the invention of claim 7, a polycarbonate resin plate is used as the decorative plate. As a result, the door panel can be provided with lighting and transparency, and is lighter and easier to process than glass and ground glass, is easily fixed by a fixing member, and has less damage in the manufacturing process. Can be further improved.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
1 to 3 are explanatory views of a door panel (A) according to an embodiment of the present invention. The door panel (A) is composed of decorative panels (1) (1) arranged on the left and right and a decorative plate (2) made of a frosted glass-like polycarbonate resin plate arranged in the center portion. 1) (1) and the decorative plate (2) are formed in a simple design that can be passed from top to bottom, respectively, as shown in FIG.
[0015]
The decorative panels (1) and (1) are provided between the inner and outer vertical bars (a) and (3b) and between the vertical bars (3a) and (3b) as shown in FIGS. Hollow core member (3) formed by a plurality (eight in the figure) of horizontal rail members (3c), reinforcing plate members (3d) provided on the upper and lower portions and the knob mounting portion, and this core member It is formed of a V-cut decorative board surface decorative material (4) covering the periphery of (3).
[0016]
The inner vertical bar (3a) of the core (3) is composed of three plate members (3a1), (3a2), and (3a3) arranged so as to surround both end portions (2a) of the decorative plate (2). Each of the three plate members (3a1), (3a2), and (3a3) is bonded and bonded to both ends (2a) of the decorative plate (2) in a fitted state. Then, in a portion where the inner vertical crosspiece (3a) of the core material (3) and both end portions (2a) of the decorative plate (2) overlap, a penetration penetrating from one surface of the core material (3) to the other surface. A hole is formed, and a fixing member (5) made of a dowel is driven into the through hole, whereby the core material (3) and the decorative plate (2) are firmly fixed.
[0017]
Since the periphery of the core material (3) is covered with the surface decorative material (4) made of a V-cut decorative board as described above, the dowels and dowel holes serving as the fixing members (5) are formed in the core material (3). The exposed part exposed on the surface of the surface is surely covered with the surface decorative material (4).
[0018]
Here, using the hollow frame as the core material (3) has an advantage that the door panel can be formed lightweight. However, the present invention is not limited to this. For example, a hollow body between the vertical crosspieces (a) and (3b) is filled with a honeycomb body to improve strength and surface compressive strength, and a fiber mat-like material or a resin foam is used. It is also possible to use a material which is filled with a heat insulating material and has improved heat insulating properties. Further, although it is heavy, a solid wood material made of wood, plywood, MDF, laminated wood, or a composite material thereof may be used.
[0019]
Further, in the above embodiment, the joint between the core material (3) and the both end portions (2a) of the decorative plate (2) is performed by three sheets forming the vertical crosspiece (3a) inside the core material (3). Although the example in which the plate members (3a1), (3a2), and (3a3) are bonded and joined in the fitted state has been described, the present invention is not limited to this. It may be formed, and both end portions (2a) of the decorative plate (2) may be inserted into the concave portions and joined in a fitted state. At the time of joining, it is preferable to use an adhesive in order to secure the joining. However, when the joining state can be sufficiently maintained only by fitting, the use of the adhesive is unnecessary.
[0020]
Furthermore, in the above embodiment, the inner side end of the core member (3) and both side ends (2a) of the decorative plate (2) are firmly fixed in a penetrating state by using a dowel for the fixing member (5). Although a simple example has been shown, the present invention is not limited to this example. For example, the core material (3) may be fixed in a semi-penetrating state from at least one side surface (2a) of the decorative plate (2) to the other surface. Not only dowels but also screws or screws may be used as the fixing member (5) for fixing.
[0021]
Further, in the above-described embodiment, an example in which a polycarbonate resin plate is used as the decorative plate (2) has been described. However, such a polycarbonate resin plate can provide the decorative plate (2) with lighting and transparency similarly to glass. It is preferable because it has advantages that it is lighter than glass, has strength and toughness, has good adhesiveness and workability, and hardly causes damage such as cracks. However, the decorative plate (2) is not limited thereto, and for example, a wooden decorative plate, a transparent or translucent resin plate of glass, acrylic resin, styrene resin, or the like can be used.
[0022]
Further, in the above embodiment, the example in which the V-cut decorative board is used as the surface decorative material (4) has been described. As shown in FIG. 7, this V-cut decorative board is made by attaching a sheet-like decorative material such as a synthetic resin decorative sheet or a veneer to the surface of a thin substrate made of a plywood, an MDF, a volcanic glassy multilayer board, or the like. A so-called V-shaped groove or arc-shaped groove (7) extending from the back side to the sheet-shaped decorative material is formed at a predetermined position by cutting, and is thick so that a dowel hole or a screw hole is formed. Even if there is a slight protrusion or depression of the screw head, it can be surely prevented from appearing on the surface of the door panel (A). In addition, since the core material (3) has a moderate strength, even if the core material (3) is a hollow framework as in the present embodiment, the core material (3) preferably has a sufficient strength against external force as a surface material. When the core material is made of the above-mentioned solid wood material and has a sufficient strength against external force on the entire surface, a sheet-like decorative material such as a synthetic resin decorative sheet or veneer is used as the surface decorative material (4). Can also be used.
[0023]
Next, an embodiment of a method for manufacturing a door panel (A) according to the present invention will be described with reference to FIGS. In FIG. 4, first, an adhesive is applied to a concave portion (6) provided on an end face of an inner side end (3a) of a framework hollow core material (3), and a side end of a decorative plate (2) made of polycarbonate resin is applied. The portion (2a) is fitted into the concave portion (6) and is adhesively fixed, and the decorative plate (2) is joined to the core material (3) in a fitted state.
[0024]
Next, as shown in FIG. 5, a plurality of core members (3) extend from one side of the inner side end (3a) through the side end (2a) of the decorative plate (2) to the other side. A dowel hole (5a) is formed, and the dowel (5) is embedded in the dowel hole (5a) to firmly fix the decorative plate (2) to the core material (3).
[0025]
Next, as shown in FIG. 7, a surface decorative material (4) composed of a V-cut decorative board shown in FIG. 6 is applied to the core material (3) corresponding to the V-cut portion (7) on the peripheral surface of the core material (3). ), The door panel (A) according to the present invention can be manufactured with high productivity by adhesively fixing it with an adhesive so as to come into contact with the corner portion.
[0026]
Here, the step of joining the decorative plate (2) to the first core material (3) in a fitted state may be performed as shown in FIGS. That is, the inner vertical bar (3a) of the core (3) is composed of three plate members (3a1), (3a2), and (3a3), and the both end portions (2a) of the decorative plate (2) are vertically arranged. Sandwich with the plate materials (3a1) and (3a2), fill the space with the plate material (3a3), and pressurize or heat press with an adhesive to join the core material (3) and the decorative plate (2) in a fitted state. Is what you do. In this case, it is not necessary to form the concave portion (6) in the inner vertical crosspiece (3a), and the decorative plate (2) and the core material (3) can be firmly bonded to each other by pressing. preferable.
[0027]
【The invention's effect】
As described above, according to the door panel according to the first aspect of the present invention, the left and right ends of the decorative plate are joined to the inside end surfaces of the core material of the decorative panel, and this portion is penetrated by the fixing member. Since the fixing member is fixed and the exposed portion of the fixing member exposed on the surface of the core material is covered with a surface decorative material, the core material and the decorative plate can be fixed very firmly, and the decorative material can be fixed on the surface. Since there is no need to attach a cap or the like, the decorativeness is not reduced. In addition, it has become possible to form door panels of various designs, which have been difficult to fix firmly without reducing decorativeness, with high productivity.
[0028]
According to the door panel of the second aspect of the present invention, since the V-cut decorative board is used as the surface decorative material, the fixing member exposed on the core material surface is more reliably covered with the thick V-cut decorative material. In addition, a V-cut portion positioned in advance is applied to the corner of the core material, and the surface decorative material can be fixed to the core material by bending along the surface, so that it can be manufactured with higher productivity.
[0029]
According to the door panel of the third aspect of the present invention, since the polycarbonate resin plate is used as the decorative plate, it is possible to provide the door panel with daylighting and light-transmitting properties. It is lighter in weight and can be easily processed and fixed by a fixing member, and damage in the manufacturing process can be reduced.
[0030]
According to the method of manufacturing a door panel according to the invention of claim 4, a step of joining both end portions of the decorative plate to the inside end surface of the core material in a fitted state, and forming the joint portion into a penetrating state by a fixing member. Since the step of fixing and the step of sequentially covering the peripheral surface of the core material including the exposed portion of the fixing member with the surface decorative material are provided, the decorative panel and the decorative plate are not impaired in the decorativeness of the decorative panel surface. Thus, a door panel that is firmly joined and fixed can be manufactured very well.
[0031]
According to the method of manufacturing a door panel according to the fifth aspect of the present invention, in the invention of the fourth aspect, the core material at the inner side end is formed of a plurality of plates, and both side ends of the decorative plate are interposed between the plates. Since both ends of the decorative plate are joined to the inner end surface of the core material by inserting and bonding, the both end portions of the decorative plate can be securely joined and held to the inner end surface of the core material, The processing operation in the subsequent processing step is facilitated, and the productivity of the door panel can be further improved.
[0032]
According to the method for manufacturing a door panel according to the sixth aspect of the present invention, in the invention of the fourth or fifth aspect, since the V-cut decorative board is used as the surface decorative material, it is positioned in advance at the corner of the core material. By applying the V-cut part and bending along the surface of the core material to fix the surface decorative material to the core material, even after fixing the decorative plate to the core material, the surface decorative material is preferably applied to the core material with an adhesive or the like. Can be fixed to Further, since the V-cut decorative board is formed by sticking a decorative sheet on the surface of the base material, the V-cut decorative board has a thickness and can surely cover the exposed portion of the fixing member exposed on the surface of the core material.
[0033]
According to the method for manufacturing a door panel according to the sixth aspect of the present invention, in the inventions of the fourth to sixth aspects, since the polycarbonate resin plate is used as the decorative plate, the door panel is provided with daylighting and transparency. Of course, it is lighter and easier to process than glass and ground glass, is easily fixed by a fixing member, and has little damage in the manufacturing process, so that the productivity of the door panel can be further improved.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a state in which a core material and a decorative plate of a door panel (A) according to an embodiment of the present invention are joined.
FIG. 2 is an explanatory view showing a horizontal section of a door panel (A) according to an embodiment of the present invention.
FIG. 3 is an explanatory diagram showing a surface appearance of a door panel (A) according to an embodiment of the present invention.
FIG. 4 is an explanatory view showing a method for manufacturing the door panel (A) according to the embodiment of the present invention.
FIG. 5 is an explanatory diagram showing a method for manufacturing the door panel (A) according to the embodiment of the present invention.
FIG. 6 is an explanatory view showing a method for manufacturing the door panel (A) according to the embodiment of the present invention.
FIG. 7 is an explanatory view showing a method of manufacturing the door panel (A) according to the embodiment of the present invention.
FIG. 8 is an explanatory view showing a modification of the method of manufacturing the door panel (A) according to the embodiment of the present invention.
[Explanation of symbols]
(A) Door panel (1) Decorative panel (2) Decorative plate (3) Core material (4) Surface decorative material (5) Dowel

Claims

A door panel comprising left and right decorative panels comprising a surface decorative material and a core material, and a decorative plate having a thickness smaller than the core material, wherein left and right side edges of the decorative plate are on the inner side of the decorative panel core material. The decorative panel is joined to the decorative panel core by a fixing member that is joined to the end face in a fitted state and penetrates the left and right ends of the decorative plate from one side surface of the inner side end to the other side surface of the core side. A door panel comprising a decorative plate integrally fixed, and an exposed portion of the fixing member exposed on the surface of the core material covered with a surface decorative material.

The door panel according to claim 1, wherein the surface decorative material is a V-cut decorative panel.

3. The door panel according to claim 1, wherein the decorative plate is made of a polycarbonate resin plate.

Joining both end portions of the decorative plate thinner than the core material to the inner side end surfaces of the core materials of the left and right decorative panels composed of the surface decorative material and the core material, and the joined core material A step of fixing the inner side end and both side ends of the decorative plate with a fixing member such that the left and right ends of the decorative plate penetrate from one surface of the core toward the other surface, Covering the surface of the core material to which the decorative plate is fixed with a surface decorative material so as to cover the exposed portion of the fixing member.

The core material on the inner side end is formed of a plurality of plates, and the both ends of the decorative plate are fitted into the inner side end surface of the core by sandwiching and bonding both ends of the decorative plate between the plates. The method for manufacturing a door panel according to claim 4, wherein the door panel is joined in a state.

The method for manufacturing a door panel according to claim 4, wherein the surface decorative material is a V-cut decorative board.

7. The method for manufacturing a door panel according to claim 4, wherein the decorative plate is made of a polycarbonate resin plate.