Frame and method for manufacturing the frame

Abstract

The present invention provides a frame and its manufacturing method that offer excellent water resistance and durability while suppressing deterioration of design. Furthermore, it provides a frame and its manufacturing method that can be supplied inexpensively and stably. [Solution] The frame 100 has an L-shaped cross-section and consists of a core material 5 made of water-resistant particleboard, a medium-density fiberboard 6 laminated on the surface of the core material 5 via adhesive, and a decorative sheet 6 attached to the surface of a wood-based material 7 made of the core material 5 and the medium-density fiberboard 6. The frame 100 has a bent portion 3 and a top portion 1 and a side portion 2 with the bent portion 3 as the boundary. The thickness of the medium-density fiberboard 6 is thinner than the thickness of the core material 5, and the entire surface of the wood-based material 7 and at least all end grain 7a, 7b in the width direction of the wood-based material 7 are covered and attached with the decorative sheet 6 to provide water resistance.

Description

Technical Field

[0001] The present invention relates to a door frame and a method for manufacturing the same.

Background Art

[0002] There is a door frame that can be easily retrofitted to the end of an entrance or the like by stacking and fixing an L-shaped door frame on a rectangular door frame provided at the entrance or the like. The cost of solid wood used for such a door frame has been increasing with the depletion of wood resources. In recent years, instead of solid wood, wood materials such as plywood have been used as the core material of the door frame (Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, the cost of plywood, which is made by laminating and compressing multiple thin plates, is also increasing with the further depletion of wood resources. By the way, a door frame that can be retrofitted is desired to have water resistance and durability. If the water resistance of the core material of the door frame that can be retrofitted is low, warping, twisting, and cracking will occur due to water absorption and moisture absorption. From this, lifting, tearing, and peeling of the decorative sheet on the door frame surface will occur. Furthermore, the surface will change color due to mold growth or the like due to moisture absorbed from the peeled part, and there is a concern about a decrease in design quality.

[0005] An object of the present invention is to provide a door frame excellent in water resistance and durability and capable of suppressing a decrease in design quality, and a method for manufacturing the same. Another object is to provide a door frame that is inexpensive and can be stably supplied, and a method for manufacturing the same.

Means for Solving the Problems

[0006] The frame of the present invention, which solves the above problems, is an L-shaped frame in cross-section comprising a core material made of water-resistant particleboard, a medium-density fiberboard laminated on the surface of the core material via an adhesive, and a decorative sheet attached to the surface of a wood-based material made of the core material and the medium-density fiberboard, wherein the frame has a bent portion and a top portion and a side portion with the bent portion as the boundary, the thickness of the medium-density fiberboard is thinner than the thickness of the core material, and the entire surface of the wood-based material and at least all the ends in the width direction of the wood-based material are covered and attached with the decorative sheet to be water-resistant. The above configuration suppresses warping, twisting, and cracking caused by water and moisture absorption, and also prevents the decorative sheet from peeling off. Furthermore, it suppresses discoloration caused by mold growth due to moisture absorbed from the peeling of the decorative sheet. These effects suppress the deterioration of the frame's design and contribute to improved durability. In addition, the above configuration allows for low cost, stable supply, and contributes to environmental protection.

[0007] The present invention, which solves the above problems, is a method for manufacturing a frame and includes the steps of: laminating a core material and a medium-density fiberboard with an adhesive; attaching a decorative sheet to a predetermined position on the back surface of the wood base material, wrapping the surface and end grain in the width direction of the wood base material; cutting and forming a bent groove parallel to the width direction on the back surface of the wood base material to a certain depth in the medium-density fiberboard; further cutting and forming a ventilation groove parallel to the width direction on the back surface of the wood base material to a certain depth in the core material; and then joining the bent grooves to form a beveled bent portion.

[0008] According to the above configuration, by being attached to the back of the wood substrate while wrapped around it, peeling and lifting from the edges of the decorative sheet can be prevented. In addition, moisture can be easily released through the grooves, making it less likely for moisture to accumulate in the wood substrate, and an effect of suppressing discoloration due to mold growth can be obtained. Furthermore, by forming a folding groove in only one place, it is possible to manufacture the frame in a shorter period of time compared to manufacturing methods in which multiple grooves are formed in the substrate, resulting in improved productivity and reduced manufacturing costs.

[0009] The present invention, which solves the above problems, is a method for manufacturing a frame and includes the steps of: laminating the core material and the medium-density fiberboard via an adhesive; attaching a moisture-proof sheet to the back surface of the wood base material; attaching a decorative sheet to the end grain of the entire surface and periphery of the wood base material up to a predetermined position on the back surface of the wood base material; cutting and forming a bending groove parallel to the width direction on the back surface of the wood base material to a certain depth in the medium-density fiberboard, and then joining the bending groove to form a beveled bent portion.

[0010] According to the above configuration, the wood base material is completely covered by the sheets attached to both sides, suppressing moisture absorption from the outside, preventing expansion and contraction of the wood base material, and allowing for stable installation. Furthermore, by attaching the decorative sheet while it is wrapped around the back of the wood base material, peeling and lifting from the edges of the decorative sheet can be prevented. In addition, by forming a folding groove in only one place on the base material of the frame, it is possible to manufacture the frame in a shorter time compared to a manufacturing method in which grooves are formed on both ends of the base material, resulting in improved productivity and reduced manufacturing costs. [Effects of the Invention]

[0011] The frame and its manufacturing method of the present invention offer excellent water resistance and durability, and suppress deterioration of design aesthetics. Furthermore, the frame and its manufacturing method of the present invention can be supplied inexpensively and stably. [Brief explanation of the drawing]

[0012] [Figure 1] (a) is a perspective view showing a frame according to one embodiment of the present invention, and (b) is a side view showing a frame according to one embodiment of the present invention. [Figure 2] This diagram shows an example of the manufacturing process for a door frame. [Figure 3] This diagram shows an example of the manufacturing process for a door frame. [Modes for carrying out the invention]

[0013] A preferred embodiment of the frame 100 of the present invention will now be described. The frame 100 shown in Figure 1 is installed by covering and fixing it to the surface of an existing square frame. As shown in Figure 1(a), the frame 100 is bent at the bending portion 3 and has a top portion 1 and side portions 2, forming an L-shape in side view. As shown in Figure 1(b), the frame 100 is composed of a core material 4 having a certain thickness, an appropriate board material such as a medium-density fiberboard 5 laminated on the surface of the core material 4, and a decorative sheet 6 attached to the surface of the medium-density fiberboard 5. Reference numerals in the figures have been omitted as appropriate.

[0014] The core material 4 is a roughly rectangular flat plate before being bent into an L-shape at the bending point. The dimensions of the core material 4 before bending are approximately 2m or 3m in width and 100mm to 300mm in length. The thickness of the core material 4 can be freely set and is not limited as long as it facilitates the formation of the grooves described later, but a thickness of approximately 9mm is usually used. As the material for the core material 4, water-resistant particleboard is used, and it is preferable that the particleboard conforms to the JIS standard for water resistance, specifically classification as water-resistant 2 (P type). This is because the higher the water resistance, the more effective it is against decay or mold growth due to moisture movement. The particleboard also has a density of 0.4g / cm³. 3 ~0.9g / cm 3 It is preferable to use a particleboard with a density of 0.4 g / cm³. 3 If the density is less than 0.9 g / cm³, the particleboard will not only lack sufficient strength, but the density of the particleboard will also be less than 0.9 g / cm³. 3 Exceeding this limit is undesirable because it results in a heavier core material that reduces workability.

[0015] Before bending, the medium-density fiberboard 5 is a roughly rectangular flat plate with the same length and width as the core material 4. It is laminated onto the surface of the core material 4 via adhesive, forming a multi-layered wood base material 7 consisting of the core material 4 and the medium-density fiberboard 5. While a thinner medium-density fiberboard 5 is preferable considering cost and ease of manufacturing, its thickness can be freely set as long as it is easy to bend. Typically, thicknesses of around 2.5 mm to 5.5 mm are used.

[0016] The decorative sheet 6 is a sheet having the same length and width as or larger in length and width than the wooden base material 7, and is adhered to the surface of the wooden base material 7 via an adhesive. The shape of the decorative sheet 6 is not limited as long as it can easily cover the wooden base material 7 and can be freely set. The material of the decorative sheet 6 is not particularly limited, and examples include resin sheets such as olefin sheets or vinyl chloride sheets that have excellent surface physical properties such as scratch resistance, abrasion resistance, and water resistance and have a certain thickness, and can be appropriately selected according to the installation location of the frame 100. The thickness of the decorative sheet 6 can be freely set and is not limited, but usually those of about 0.05 mm to 0.2 mm are used. In FIG. 1(b), the end portion of the decorative sheet 6 is shown. As shown in the figure, the decorative sheet 6 may cover the surface of the wooden base material 7 and the end grain 7a at both ends in the width direction W of the wooden base material 7, and may also cover one end portion of the back surface of the wooden base material 7. The decorative sheet 6 may cover all the end grains 7a, 7b (FIG. 3) on the peripheral surface of the wooden base material 7 and cover up to a predetermined position on the back surface of the wooden base material 7.

[0017] The adhesive used here may be any of an aqueous adhesive, a resin adhesive, a hot melt adhesive, etc., and can be appropriately selected according to the types of the decorative sheet 6, the medium density fiberboard 5, and the particle board. Also, the coating amount can be appropriately selected from the viewpoints of their types and adhesiveness. In the frame 100, an adhesive is applied to the particle board and the medium density fiberboard 5 is adhered, but the coating amount of the adhesive can be reduced by about 20% compared to the case where an adhesive is applied to the plywood and the medium density fiberboard 5 is adhered.

[0018] The plate thickness of the frame 100 is not particularly limited, but for example, about 12 mm to 13 mm is desirable, and it may be set to the same thickness as the floor material (not shown) laid side by side with the frame 100. Also, in the frame 100 of the present embodiment, the side surface portion 2 is formed larger than the top surface portion 1, but it is not limited to this, and the top surface portion 1 and the side surface portion 2 can also be formed to have the same size, or the side surface portion 2 can be configured to be formed smaller than the top surface portion 1. The dimensions of each part of the frame 100 can be arbitrarily selected according to the size of the object covered by the frame 100 and the like.

[0019] The frame 100 may further form grooves (not shown) on the back surface of the woody base material to ensure air permeability. The grooves are strip grooves parallel to the width W direction of the woody base material, and about 2 to 3 grooves may be formed on the back surface of the top surface portion 1, and about 3 to 4 grooves may be formed on the back surface of the side surface portion 2. The number of grooves is not limited to about 2 to 3 grooves on the back surface of the top surface portion 1 and about 3 to 4 grooves on the back surface of the side surface portion 2 as long as air permeability can be ensured, and the number can be freely selected. To ensure air permeability, for example, strip grooves with a substantially rectangular cross-section having a width of about 3 mm to 10 mm or strip grooves with a substantially square cross-section having a width of about 3 mm to 5 mm may be formed at about 2 to 3 locations on the back surface of the top surface portion 1 and at about 3 to 4 locations on the back surface of the side surface portion 2. The depth of the grooves is not particularly limited as long as the strength of the woody base material does not decrease, but a range of about 1 mm to 10 mm is desirable, for example. In one example, to ensure air permeability, strip grooves with a rectangular cross-section having a width of 3 mm and a depth of about 1 mm may be formed at 3 locations on the back surface of the top surface portion 1 and at 4 locations on the back surface of the side surface portion 2. In one example, to ensure air permeability, strip grooves with a square cross-section having a width of 3 mm and a depth of about 3 mm may be formed at 1 location on the back surface of the top surface portion 1 and at 4 locations on the back surface of the side surface portion 2. The shape of the grooves is not limited to strip grooves substantially parallel to the width W direction of the woody base material as long as air permeability can be ensured, and a free shape can be selected.

[0020] The first manufacturing method of the frame 100 will be described. FIG. 2 is a schematic diagram showing the steps of the first manufacturing method in order. In the first step, an adhesive is applied to the surface of the core material 4 and the medium density fiberboard 5 is laminated. Then, in the second step, a decorative sheet 6 is adhered to the entire surface from end to end of the surface of the woody base material 7 to form a base material 8.

[0021] In the third step, in order to fold the base material 8 made of a woody material or the like into a mountain fold to form the folded portion 3, a folding strip groove 11 including an M-shaped cross-section is formed at the boundary with the top surface portion 1 and the side surface portion 2. Subsequently, in order to fold back both ends of the base material 8, a folding-back strip groove 12 having a substantially V-shaped cross-section is formed at the ends of the top surface portion 1 and the side surface portion 2. The grooves are cut out by a certain depth of the core material 4 and the medium density fiberboard 5 on the back surface of the base material 8. The grooves are cut using a saw blade with a V-shaped tip, but the angle of the blade tip can be appropriately changed according to the shape of the grooves. The bending groove 11 is cut parallel to the width direction of the base material 8 to a predetermined width. The central triangular portion, which is cut into a roughly M-shape in cross-section, forms a chamfered bent portion 3 when the base material 8 is folded in a mountain fold along the bending groove 11. The shape of the bending groove 11 is not limited to grooves with a roughly M-shape in cross-section, but can be formed into any shape as long as a chamfered bent portion 3 is formed when folded. On both ends of the back surface of the base material 8, a folding groove 12 with a roughly V-shaped cross-section is cut parallel to the aforementioned bending groove 11 with a predetermined width dimension to form a folded portion 9. Furthermore, if the thickness of the medium-density fiberboard 5 is between 2.5 mm and 5.5 mm, it is preferable to provide grooves not only in the core material 4 but also in the medium-density fiberboard 5, as this allows for more flexible bending at the bending portion 3 and the folded portion 9. When cutting grooves into the medium-density fiberboard 5, a thickness of approximately 0.05 mm to 0.2 mm must be left to prevent the medium-density fiberboard 5 from being cut and to prevent the decorative sheet 6 from cracking during bending. In the third step, grooves may be formed on the back surface of the wood substrate 7 to ensure breathability.

[0022] In the fourth step, the V-shaped slopes of the folding groove 12 are joined together to fold the folding groove 12 back to the back side of the base material 8, forming a folded portion 9 with the same thickness as the base material 8. By forming the folded portion 9, the ends of the top surface 1 and side surface 2 in the width direction W become ends where the ends of the wood base material 7 in the width direction W are covered with the decorative sheet 6. Next, as shown in the figure, the folding groove 11 is joined together so that the base material 8 becomes a mountain fold, forming a bent portion 3 with rounded corners.

[0023] Figure 3 is a schematic diagram showing the steps of the second manufacturing method in order. In the second manufacturing method, decorative sheets 6 are attached to the surface and a portion of the back surface of the wood substrate 7 using a wrapping technique or the like. In the first step, adhesive is applied to the surface of the core material 4 and the medium-density fiberboard 5 is laminated. Then, in the second step, a decorative sheet 6 is attached to the entire surface of the wood base material 7 from edge to edge to form the base material 8. At this time, the decorative sheet 6 is wrapped around the back side in the width direction W of the wood base material 7 and is attached to cover the back side in the width direction W of the wood base material 7 up to a predetermined appropriate position. The end surface of the wood base material 7 is processed so that the end grain 7a and a part of the back surface in the width direction W are covered with the decorative sheet 6.

[0024] In the third step, a folding groove 11, including an M-shaped cross-section, is formed at the boundary between the top surface 1 and the side surface 2 in order to fold the base material 8, which is made of wood-based material, into a mountain fold to form the folded portion 3. The groove is cut out to a certain depth from the core material 4 and medium-density fiberboard 5 on the back surface of the base material 8. The groove is cut using a saw blade with a V-shaped tip, but the angle of the blade tip can be changed as appropriate according to the shape of the groove. The bending groove 11 is cut parallel to the width direction of the base material 8 to a predetermined width. The central triangular portion, which is cut into a roughly M-shape in cross-section, forms a chamfered bent portion 3 when the base material 8 is folded in a mountain fold along the bending groove 11. The shape of the bending groove 11 is not limited to grooves with a roughly M-shape in cross-section, but can be formed into any shape as long as a chamfered bent portion 3 is formed when folded. Furthermore, if the thickness of the medium-density fiberboard 5 is between 2.5 mm and 5.5 mm, it is preferable to provide grooves not only in the core material 4 but also in the medium-density fiberboard 5, as this allows for more flexible bending at the bending portion 3 and the folded portion 9. When cutting grooves into the medium-density fiberboard 5, a thickness of approximately 0.05 mm to 0.2 mm must be left to prevent the medium-density fiberboard 5 from being cut and to prevent the decorative sheet 6 from cracking during bending. In the third step, grooves may be formed on the back surface of the wood substrate 7 to ensure breathability. In the fourth step, as shown in the figure, the base material 8 is folded in a mountain fold by joining the folding groove 11 to form a bent portion 3 with rounded corners.

[0025] A third manufacturing method of the present invention will now be described. In this third manufacturing method, only steps different from those included in the previously described manufacturing method will be described. All steps described in the first manufacturing method may also be included in the third manufacturing method. Furthermore, the definitions of terms used in the first manufacturing method are the same in the third manufacturing method.

[0026] The following steps are performed in place of the first and second steps in the first manufacturing method. In the first step, adhesive is applied to the back surface of the core material 4 and a moisture-proof sheet 10 (not shown) is attached to the entire surface from edge to edge of the back surface. In the second step, a decorative sheet 6 is attached to the entire surface from edge to edge of the medium-density fiberboard 5, and then adhesive is applied to the surface of the core material 4 and the medium-density fiberboard 5 is laminated.

[0027] A fourth manufacturing method of the present invention will now be described. In this fourth manufacturing method, only steps different from those included in the previously described manufacturing method will be described. All steps described in the second manufacturing method may also be included in the fourth manufacturing method. Furthermore, the definitions of terms used in the second manufacturing method are the same in the fourth manufacturing method.

[0028] The following steps are performed before the first step in the second manufacturing method: A moisture-proof sheet 10 is attached to the entire surface of the back of the wood substrate 7 from edge to edge. In the second step, a decorative sheet 6 is attached to the entire surface of the wood substrate 7 from edge to edge to form the substrate 8. At this time, the decorative sheet 6 covers the end grain 7a and 7b of the entire periphery of the wood substrate 7 and is attached up to a predetermined position on the back side of the wood substrate 7. The ends of the top surface 1 and the side surface 2 in the width direction W and length direction L are the ends of the wood substrate 7 where the end grain 7a and 7b are covered by the decorative sheet 6.

[0029] Note that the configuration and shape of the bent section 3, the folded section 9, the bent groove 11, and the folded groove 12 are not limited to the illustrated example. Also, the installation location of the frame 100 is not limited to the entrance threshold, but may be provided on the treads of stairs, etc.

[0030] The function and effect of frame 100 will be explained. In frame 100, water-resistant particleboard is used for the core material 4. Particleboard is made by molding and heat-pressing using adhesive with small pieces of wood as the main raw material, resulting in a uniform material that is less prone to warping and cracking and has excellent durability. By using water-resistant particleboard in frame 100, warping, twisting, and cracking due to water absorption and moisture absorption can be suppressed, and the peeling of the decorative sheet 6 can also be prevented. Furthermore, discoloration caused by mold growth due to moisture absorbed from the peeling of the decorative sheet 6 can be suppressed.

[0031] The decorative sheet 6 is applied not only to the entire surface of the base material 8, but also to cover at least the end grain 7a of the wood base material 7. This prevents water and moisture absorption from both the surface and the end grain 7a of the base material 8. Furthermore, by applying the decorative sheet 6 while wrapped around the back surface of the wood base material 7, peeling and lifting from the edges of the decorative sheet 6 can be prevented. These effects become more pronounced as the covering area of ​​the decorative sheet 6 increases.

[0032] In frame 100, grooves are formed on the back surface of the wood base material 7 to ensure ventilation, which allows moisture to easily escape through the grooves. This prevents moisture from accumulating in the wood base material 7 and suppresses discoloration caused by mold growth.

[0033] The frame 100 has excellent moisture-proof properties due to the action of the moisture-proof sheet 10 attached to its back surface. Furthermore, since the decorative sheet 6 is attached to cover the entire end grain 7a and 7b of the surrounding surface of the wood base material 7, the wood base material 7 is completely covered with the sheet, suppressing moisture absorption from the outside. Due to the action of the sheets attached to both sides of the wood base material 7, expansion and contraction of the wood base material 7 are suppressed, allowing the frame 100 to be installed stably on the flooring material. These effects help to suppress the deterioration of the aesthetic appeal of frame 100 and contribute to improved durability.

[0034] Frame 100 utilizes low-cost medium-density fiberboard 5 and particleboard, manufactured by reusing construction waste and wood scraps, as wood-based materials 7. This allows it to be offered at a lower cost compared to using solid wood or plywood, while also ensuring a stable supply and contributing to environmental protection.

[0035] In frame 100, adhesive is applied to particleboard and then the medium-density fiberboard 5 is bonded to it. However, the amount of adhesive applied can be reduced by about 20% compared to when adhesive is applied to plywood and then the medium-density fiberboard 5 is bonded to it. This reduces manufacturing costs.

[0036] In manufacturing method 2, in which a bent groove 11 is formed in only one place on the base material 8 of the frame 100, the frame 100 can be manufactured in a shorter time compared to manufacturing method 1, in which grooves are formed on both ends of the base material 8, resulting in improved productivity and reduced manufacturing costs.

[0037] The above embodiments illustrate possible forms of the frame according to the present invention. The above description of embodiments is not intended to limit the possible forms of the frame according to the present invention. The frame according to the present invention may take forms different from those illustrated in the embodiments. [Explanation of symbols]

[0038] 1 Top section 2 Side part 3 Bend part 4 Core material 5 Medium-density fiberboard 6 Decorative Sheet 7 Wood base material 7a End grain 7b Wood 8 Base material 9 Turning section 10 Moisture-proof sheet 11 Bent groove 12 Turned groove 100 frames W (width direction) L (Length direction)

Claims

1. The core material is made of water-resistant particleboard, A medium-density fiberboard laminated on the surface of the core material via an adhesive, A frame with an L-shaped cross-section, comprising the core material and a decorative sheet attached to the surface of a wood-based material made of the medium-density fiberboard, The frame comprises a bent portion and a top portion and a side portion with the bent portion as the boundary. The thickness of the medium-density fiberboard is thinner than the thickness of the core material. A water-resistant frame in which the entire surface of the wood substrate and at least all edges in the width direction of the wood substrate are covered and attached with the decorative sheet.

2. A step of laminating the core material and the medium-density fiberboard with an adhesive, The process involves wrapping the surface and the end grain in the width direction of the wood substrate and attaching the decorative sheet to a predetermined position on the back surface of the wood substrate, The wood substrate is formed by cutting and creating a bent groove parallel to the width direction on the back surface to a certain depth in the medium-density fiberboard, and further cutting and creating a ventilation groove parallel to the width direction on the back surface of the wood substrate to a certain depth in the core material. The method for manufacturing a frame according to claim 1, further comprising the step of joining the aforementioned bending grooves to form a beveled bending portion.

3. A step of laminating the core material and the medium-density fiberboard via an adhesive, The process involves attaching a moisture-proof sheet to the back surface of the aforementioned wood substrate, The process involves wrapping the surface of the wood substrate and the end grain of the entire periphery and attaching the decorative sheet to a predetermined position on the back surface of the wood substrate, The wood substrate is formed by cutting a bent groove parallel to the width direction on the back surface to a certain depth in the medium-density fiberboard. The method for manufacturing a frame according to claim 1, further comprising the step of joining the aforementioned bending grooves to form a beveled bending portion.

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