Door structure and door manufacturing method

Abstract

This invention provides a door structure suitable for mass production of door bodies using adhesive bonding methods. [Solution] In a door structure comprising a frame assembly made up of a horizontal frame consisting of an upper frame 3 and a lower frame 4, left and right vertical frames and an intermediate vertical frame 7, end notches are formed at the longitudinal ends of the horizontal frame, engaging portions are formed at the longitudinal ends of the left and right vertical frames to engage with the end notches from the depth direction to constitute a first engaging state, intermediate notches 34 and 44 are formed in the longitudinal middle portion of the horizontal frame, and engaging portions are formed at the longitudinal end of the intermediate vertical frame 7 to engage with the intermediate notches 34 and 44 from the depth direction to constitute a second engaging state, the first engaging state is an engaging state in which the inward tilting of the vertical frame is restricted, and the second engaging state is an engaging state in which the tilting of the intermediate vertical frame 7 in both directions is restricted when the frame assembly is laid flat.

Description

Technical Field

[0001] The present invention relates to a door body structure and a method for manufacturing a door body.

Background Art

[0002] In a steel door, a method of assembling a frame material (main frame, middle frame) and a surface material with welding or an adhesive is generally known. Welding work requires skilled techniques, and there are also problems of thermal distortion and finish, making it a time-consuming and laborious operation for production. In recent years, an assembly method for a door body using an adhesive without welding work (so-called "adhesive method") has been added to the public building construction standard specification.

[0003] In the adhesive method, different from the welding method and the structural joint tape method, a drying time is required until the adhesive that bonds the surface material and each frame material hardens. During this time until the adhesive hardens, it is necessary to prevent the frame material from falling, and if the frame material is displaced, the adhesive quality in the door body structure may deteriorate.

[0004] Patent Document 1 discloses a door body by the adhesive method, but how to mass-produce the door body using the adhesive method has become an issue.

Patent Document 1

Disclosure of the Invention

Problems to be Solved by the Invention

[0005] An object of the present invention is to provide a door body structure and a method for manufacturing a door body adapted to mass production of a door body in the adhesive method.

Means for Solving the Problems

[0006] The technical means adopted by the present invention is In a door body structure including a frame assembly assembled from upper and lower horizontal frames, left and right vertical frames, and one or more intermediate vertical frames, End notches are formed at the longitudinal ends of the horizontal frame, and engagement portions are formed at the longitudinal ends of the left and right vertical frames, which engage with the end notches from the depth direction to form a first engagement state. An intermediate notch is formed in the middle of the length of the horizontal frame, and an engaging portion is formed at the end of the intermediate vertical frame in the length direction, which engages with the intermediate notch from the depth direction to constitute a second engaged state. The first engagement state is such that, when the frame assembly is laid flat, the inward tilting of the vertical frame is restricted. The second engagement state is such that, when the frame assembly is laid flat, the tilting of the intermediate vertical frame in both directions is restricted. It is a door structure.

[0007] In one embodiment, the upper frame, which is the horizontal frame, comprises a top surface and a pair of visible edges, The aforementioned vertical frame and the aforementioned intermediate vertical frame each comprise a face surface and a pair of facing edges, The end notches and the intermediate notches are upper notches formed opposite to a pair of visible edges of the upper frame. The upper ends of the pair of visible edges of the vertical frame and the intermediate vertical frame engage with the upper notch from the depth direction, forming an upper first engagement state and an upper second engagement state.

[0008] In one embodiment, the lower frame, which is the horizontal frame, comprises a top surface and a pair of visible edges, The aforementioned vertical frame and the aforementioned intermediate vertical frame each comprise a face surface and a pair of facing edges, The end notch and the intermediate notch are lower notches formed continuously on the upper surface and the upper end of at least one of the visible edges of the lower frame. The projections extending from the lower ends of the depth surfaces of the vertical frame and the intermediate vertical frame engage with the lower notch from the depth direction, forming a lower first engagement state and a lower second engagement state. In one embodiment, the upper notch is wider in the visible direction, and the lower notch is narrower in the visible direction. In one embodiment, the lower frame, which is the horizontal frame, comprises a bottom surface and a pair of visible edges, The aforementioned vertical frame and the aforementioned intermediate vertical frame each comprise a face surface and a pair of facing edges, The end cutout and the intermediate cutout are lower cutouts formed opposite to a pair of visible edges of the lower frame. The lower ends of the pair of visible edges of the vertical frame and the intermediate vertical frame engage with the lower notch from the depth direction, forming a lower first engagement state and a lower second engagement state.

[0009] In one embodiment, the door structure includes a first surface material and a second surface material, The first surface material comprises a first visible surface that forms the first surface portion of the door body, and a pair of first visible edges. The second surface material comprises a second facing surface that forms the second surface portion of the door body, and a pair of second facing edges. The first visible surface and the second visible surface are bonded to the visible edge of the frame assembly, and the first and second visible edges abut against the outer surface of the visible edge of the vertical frame.

[0010] The technical means employed in this invention are: A method for manufacturing a door body from multiple frame materials including upper and lower horizontal frames and three or more vertical frames, a first surface material, and a second surface material, The frame material comprises a face surface and a pair of visible edges, The first surface material comprises a first visible surface that forms the first surface portion of the door body, and a pair of first visible edges. The second surface material comprises a second facing surface that forms the second surface portion of the door body, and a pair of second facing edges. A first step is to assemble the frame material by applying adhesive between the first visible surface of the first surface material in a horizontal position and one visible edge of the frame material, thereby forming a flat-lying frame assembly, A second step involves applying adhesive between the second visible surface of the second surface material and the other visible edge of the frame material, and covering the frame assembly with the second surface material. A third step involves curing the adhesive to bond the frame assembly to the first surface material and the second surface material, It consists of, In the previous step, Multiple notches are formed along the length of the horizontal frame, and engaging portions formed at the ends of the vertical frame along the length are engaged with the notches from the depth direction to constitute an engaged state. In the above steps 1, 2 and 3, The aforementioned engagement state restricts the tilting of the vertical frame.

[0011] In one embodiment, the three or more vertical frames consist of left and right vertical frames and one or more intermediate vertical frames. In the previous step, End notches are formed at the longitudinal ends of the horizontal frame, and engaging portions formed at the longitudinal ends of the left and right vertical frames are engaged with the end notches from the depth direction to constitute a first engaged state. An intermediate notch is formed in the middle of the length of the horizontal frame, and an engaging portion formed at the end of the intermediate vertical frame in the length direction is engaged with the intermediate notch from the depth direction to constitute a second engaged state. In the above steps 1, 2 and 3, The first engagement state restricts the inward tilting of the vertical frame. The first and second projection edges restrict the outward tilting of the vertical frame. The second engagement state restricts the tilting of the intermediate vertical frame in both directions.

[0012] In one embodiment, the upper frame and lower frame, which are the horizontal frames, each have a top surface and a pair of visible edges. The end notch portion includes an upper end notch portion formed oppositely to a pair of finding sides of the upper frame, and a lower end notch portion formed continuously at the upper surface of the lower frame and at least at the upper end of one of the finding sides. The upper end portion of the vertical frame serves as an upper engaging portion, engages with the upper end notch portion from the prospective direction to form an upper first engaging state. The prospective protruding piece protruding from the lower end of the prospective surface of the vertical frame serves as a lower engaging portion, engages with the lower end notch portion from the prospective direction to form a lower first engaging state. The intermediate notch portion includes an upper intermediate notch portion formed oppositely to a pair of finding sides of the upper frame, and a lower intermediate notch portion formed continuously at the upper surface of the lower frame and at least at the upper end of one of the finding sides. The upper end portion of the intermediate vertical frame serves as an upper engaging portion, engages with the upper intermediate notch portion from the prospective direction to form an upper second engaging state. The prospective protruding piece protruding from the lower end of the prospective surface of the intermediate vertical frame serves as a lower engaging portion, engages with the lower intermediate notch portion from the prospective direction to form a lower second engaging state.

[0013] In one aspect, the third step includes: a step of conveying an assembly including a plurality of frame members, a first surface member, and a second surface member to a thermocompression means; a step of curing an adhesive with the thermocompression means; and includes.

Advantages of the Invention

[0014] In the present invention, a door structure comprising a frame assembly made up of upper and lower horizontal frames and multiple vertical frames (left and right vertical frames and one or more intermediate vertical frames), the engaging portion at the upper end of the vertical frame engages with the notch in the upper frame from the depth direction to form an upper engaging state, and the engaging portion at the lower end of the vertical frame engages with the notch in the lower frame from the depth direction to form a lower engaging state. The tilting and lateral displacement of the vertical frames are restricted by the upper and lower engaging states. Therefore, since tilting and lateral displacement of the vertical frames are restricted in the stage before the adhesive hardens during the manufacturing process of the door (especially when the frame assembly is mechanically transported), a door structure and a door manufacturing method suitable for mass production of door bodies can be provided. [Brief explanation of the drawing]

[0015] [Figure 1] This is a front view of the door body according to this embodiment. [Figure 2] This is a front view of the door structure according to this embodiment (with the first surface material removed). [Figure 3] This is a magnified view of a portion of Figure 2. [Figure 4] This is a magnified view of a portion of Figure 2. [Figure 5] Figure 2 shows a cross-sectional view taken along arrow A, and a cross-sectional view taken along arrow B (partial view). [Figure 6] This is a longitudinal cross-sectional view taken along arrow C in Figure 2. [Figure 7] This is a diagram of the upper frame. [Figure 8] This is a diagram of the lower frame. [Figure 9] This diagram shows vertical frames (including the middle vertical frame). [Figure 10] This is a front view of a door structure according to another embodiment (with the first surface material removed). [Figure 11] This is a longitudinal cross-sectional view taken along arrow B in Figure 10. [Figure 12] This is a cross-sectional view taken along arrow A in Figure 10. [Figure 13] This diagram shows the heat-sealing process for the door body. [Figure 14] The images show a front view of a door structure according to another embodiment (with the first surface material removed), a cross-sectional view taken along arrow A in the front view, and a cross-sectional view taken along arrow B in the front view. [Figure 15] This is a magnified view of a section of Figure 14. [Figure 16] This diagram shows the lower frame according to another embodiment. [Figure 17] This diagram shows a vertical frame according to another embodiment. [Modes for carrying out the invention]

[0016] [A] Door body configuration The door body consists of a frame and a surface material attached to the frame. The surface material mainly consists of a first surface material 1 that forms the outdoor side of the door body and a second surface material 2 that forms the indoor side of the door body. As shown in Figures 1 and 2, the frame, or structural member, of the door body is formed by combining four reinforcing ribs, namely an upper frame 3, a lower frame 4, and left and right vertical frames 5 and 6 in a perimeter manner, thereby forming a perimeter frame. Between the upper frame 3 and the lower frame 4, an intermediate vertical frame or central rib 7 is provided parallel to the left and right vertical frames 5 and 6. The door body is formed by bonding the first surface material 1 and the second surface material 2 to the frame of the door body. In Figure 1, hinges h are provided at intervals in the height direction on the tail end of the door body, and a handle H is provided at the midpoint in the height direction on the leading end of the door surface. In this embodiment, the frame and surface material are made of steel. In this embodiment, the door body is a hinged door, but it may also be a sliding door.

[0017] [A-1] Upper frame The upper frame 3 is a long member extending in the width direction of the door body, and has a length (visible dimension) that is approximately corresponding to the door width (visible width) and a depth that is approximately corresponding to the thickness (depth width) of the door body. As shown in Figure 7, the upper frame 3 is formed in a U-shape in cross-section from an upper surface 30, a first visible edge 31 that hangs down from one end of the upper surface 30 in the depth direction, and a second visible edge 32 that hangs down from the other end of the upper surface 30 in the depth direction.

[0018] [A-1-1] Upper end cutout At both ends of the upper frame 3 in the longitudinal direction, upper end notches 33 are formed opposite each other at both ends of the first visible edge 31 and the second visible edge 32 in the longitudinal direction. The upper end notches 33 are rectangular in shape when viewed from the front, and are defined by the upper edge 330 of the long side and the hanging edge 331 of the short side. The visible width of the upper end notches 33 is approximately the same as or greater than the visible width of the vertical frames 5 and 6.

[0019] [A-1-2] Upper intermediate cutout In the upper frame 3, at predetermined intermediate points along the length, upper intermediate notches 34 are formed opposite each other at predetermined intermediate points along the length of the first visible edge 31 and the second visible edge 32. The upper intermediate notches 34 are rectangular in shape when viewed from the front, and are defined by the upper edge 340 of the long side and the left and right hanging edges 341 and 342 of the short side. The visible width of the upper intermediate notches 34 is approximately the same as, or greater than, the visible width of the intermediate vertical frame 7. In this embodiment, the visible width of the upper end notches 33 and the visible width of the upper intermediate notches 34 are approximately the same.

[0020] [A-2] Lower frame The lower frame 4 is a long member extending in the width direction of the door body, and has a length (visible dimension) that is approximately corresponding to the door width (visible width) and a depth that is approximately corresponding to the thickness (depth width) of the door body. As shown in Figure 8, the lower frame 4 is formed in a U-shape in cross-section from an upper surface 40, a first visible edge 41 hanging down from one end of the upper surface 40 in the depth direction, and a second visible edge 42 hanging down from the other end of the upper surface 40 in the depth direction.

[0021] [A-2-1] Lower end cutout Lower end notches 43 are formed at both ends in the longitudinal direction of the lower frame 4. The lower end notches 43 consist of a narrow portion 430 that extends in the depth direction at the longitudinal end of the upper surface 40 of the lower frame 4, and a notch 431 at the upper end of the longitudinal end of the first visible edge 41, with the narrow portion 430 and the notch 431 being continuous. The visible width of the lower end notches 43 is smaller than the visible width of the upper end notches 33, and is slightly larger than the plate thickness of the visible surfaces 50 and 60 of the vertical frames 5 and 6.

[0022] [A-2-2] Lower intermediate cutout A lower intermediate notch 44 is formed at a predetermined intermediate portion in the longitudinal direction of the lower frame 4. The lower intermediate notch 44 consists of a narrow portion 440 extending in the depth direction at the midpoint of the longitudinal direction of the upper surface 40 of the lower frame 4, and a notch 441 at the upper end of the midpoint of the longitudinal end of the first visible edge 41, with the narrow portion 440 and the notch 441 being continuous. The visible width of the lower intermediate notch 44 is smaller than the visible width of the upper intermediate notch 34, and is slightly larger than the plate thickness of the depth surface 70 of the intermediate vertical frame 7.

[0023] [A-3] Vertical Frame The vertical frames 5 and 6 are elongated members that extend in the height direction of the door body, and have a length (height) that is approximately corresponding to the door height and a depth (depth) that is approximately corresponding to the thickness (depth) of the door body. The left and right vertical frames 5 and 6 are symmetrical and have essentially the same shape. As shown in Figure 2, the height of the vertical frames 5 and 6 is lower than the total height of the door body, the upper ends of the vertical frames 5 and 6 engage with the upper frame 3, and the lower ends of the vertical frames 5 and 6 engage with the lower frame 4.

[0024] The vertical frame 5 is a door-side vertical frame and, as shown in Figure 9, is formed in a U-shape in cross-section from a depth surface 50, a first facing edge 51 extending in the facing direction from one end of the depth surface 50 in the depth direction, and a second facing edge 52 extending in the facing direction from the other end of the depth surface 50 in the depth direction. The upper edge of the vertical frame 5 is formed from the upper edge 500 of the depth surface 50, the upper edge 510 of the first facing edge 51, and the upper edge 520 of the second facing edge 52. A projection 53 is formed in a hanging manner at the lower end of the depth surface 50 of the vertical frame 5, and the projection 53 protrudes below the lower edge 511 of the first facing edge 51 and the lower edge 521 of the second facing edge 52. The projection surface 50 of the vertical frame 5 forms the door-side end surface of the door body, and the edge 512 of the first projection side 51 and the edge 522 of the second projection side 52 are spaced apart from the projection surface 50 towards the door-side.

[0025] The vertical frame 6 is a door-end side vertical frame and, as shown in Figure 9, is formed in a U-shape in cross-section from a depth surface 60, a first facing edge 61 extending in the facing direction from one end of the depth surface 60 in the depth direction, and a second facing edge 62 extending in the facing direction from the other end of the depth surface 60 in the depth direction. The upper edge of the vertical frame 6 is formed from the upper edge 600 of the depth surface 60, the upper edge 610 of the first facing edge 61, and the upper edge 620 of the second facing edge 62. A projection 63 is formed in a hanging manner at the lower end of the depth surface 60 of the vertical frame 6, and the projection 63 protrudes below the lower edge 611 of the first facing edge 61 and the lower edge 621 of the second facing edge 62. The projection surface 60 of the vertical frame 6 forms the door-side end face of the door body, and the edge 612 of the first projection side 61 and the edge 622 of the second projection side 62 are spaced apart from the projection surface 60 towards the door-side.

[0026] [A-3-1] Upper end engagement part The upper ends of the vertical frames 5 and 6 (the upper ends of the visible surfaces 50 and 60, the first visible edges 51 and 61, and the second visible edges 52 and 62) are upper end engagement portions that engage with the upper end cutout portion 33 of the upper frame 3.

[0027] [A-3-2] Lower end engagement part At the lower ends of the depth surfaces 50 and 60 of the vertical frames 5 and 6, projection pieces 53 and 63 are formed in a hanging manner, and these projection pieces 53 and 63 serve as the lower engagement portion.

[0028] [A-4] Intermediate vertical frame The intermediate vertical frame 7 is a long member that extends in the height direction of the door body, and has a length (height) that is approximately corresponding to the door height and a depth (depth) that is approximately corresponding to the thickness (depth) of the door body. As shown in Figure 2, the height of the intermediate vertical frame 7 is lower than the total height of the door body, the upper end of the intermediate vertical frame 7 engages with the upper frame 3, and the lower end of the intermediate vertical frame 7 engages with the lower frame 4.

[0029] As shown in Figure 9, the intermediate vertical frame 7 is formed in a U-shape in cross-section from a depth surface 70, a first facing edge 71 extending in the facing direction from one end of the depth surface 70 in the depth direction, and a second facing edge 72 extending in the facing direction from the other end of the depth surface 70 in the depth direction. The upper edge of the intermediate vertical frame 7 is formed from the upper edge 700 of the depth surface 70, the upper edge 710 of the first facing edge 71, and the upper edge 720 of the second facing edge 72. A projection 73 is formed in a hanging manner at the lower end of the depth surface 70 of the intermediate vertical frame 7, and the projection 73 protrudes below the lower edge 711 of the first facing edge 71 and the lower edge 721 of the second facing edge 72. The projection surface 70 of the intermediate vertical frame 7 forms the door-side end face of the door body, and the edge 712 of the first projection side 71 and the edge 722 of the second projection side 72 are spaced apart from the projection surface 70 towards the door-side. In this embodiment, the shape and dimensions of the intermediate vertical frame 7 are the same as those of the vertical frame 5. Note that the orientation of the intermediate vertical frame 7 in plan view may be reversed, in which case it will be the same as the shape and dimensions of the vertical frame 6.

[0030] [A-4-1] Upper end engagement part The upper end portion of the intermediate vertical frame 7 (the upper end portion of the visible surface 70, the first visible edge 71, and the second visible edge 72) engages with the upper intermediate cutout portion 34 of the upper frame 3, forming an upper end engagement portion.

[0031] [A-4-2] Lower end engagement part A projection 73 is provided at the lower end of the depth surface 70 of the intermediate vertical frame 7, and this projection 73 serves as the lower engaging portion.

[0032] [A-5] Surface material The first surface material 1 consists of a first visible surface 10 that forms the first surface of the door body, left and right recessed edges 11 and 12 formed by bending at right angles at both ends in the width direction of the first visible surface 10, an upper edge 13 formed by bending at right angles at the upper end of the first visible surface 10, and a lower edge 14 formed by bending at right angles at the lower end of the first visible surface 10.

[0033] The second surface material 2 consists of a second visible surface 20 that forms the second surface of the door body, left and right visible edges 21 and 22 formed by bending at right angles at both ends in the width direction of the second visible surface 20, an upper edge 23 formed by bending at right angles at the upper end of the second visible surface 20, and a lower edge 24 formed by bending at right angles at the lower end of the second visible surface 20.

[0034] [B] Engagement of vertical frame and upper frame [B-1] Engagement of vertical frame and upper frame The front view shape of the upper end portions of vertical frames 5 and 6 matches the front view shape (horizontal rectangle) of the upper end cutout portion 33 of the upper frame 3. The upper end portions of vertical frames 5 and 6 act as upper engaging portions, engaging with the upper end cutout portion 33 of the upper frame 3 from the depth direction to form an upper first engaging state. The depth width of vertical frames 5 and 6 and the depth width of the upper frame 3 are approximately the same. The first visible edges 51 and 61 of vertical frames 5 and 6 and the first visible edge 31 of the upper frame 3 form the same plane, and the second visible edges 52 and 62 of vertical frames 5 and 6 and the second visible edge 32 of the upper frame 3 form the same plane.

[0035] In the upper first engagement state, the upper edge 510 of the first visible edge 51 of the vertical frame 5 is close to or in contact with the upper edge 330 of the upper end notch 33 formed on the first visible edge 31 of the upper frame 3, and the upper end portion of the edge 512 of the first visible edge 51 is close to or in contact with the hanging edge 331 of the upper end notch 33 of the upper frame 3 (see Figure 4). The upper edge 520 of the second visible edge 52 of the vertical frame 5 is close to or in contact with the upper edge 330 of the upper end notch 33 formed on the second visible edge 32 of the upper frame 3, and the upper end portion of the edge 522 of the second visible edge 52 is close to or in contact with the hanging edge 331 of the upper end notch 33 of the upper frame 3. In the upper first engagement state, the inward rotation of the upper end portion of the vertical frame 5 is restricted by the contact of one of the upper ends of the first visible edge 512 and the second visible edge 52 (the visible edge located on the upper side in the orientation when the door body is assembled) with one of the hanging edges 331 of the pair of upper end notches 33. The displacement of the vertical frame 5 toward the door tail is restricted by the contact of the upper ends of the first visible edge 512 and the second visible edge 52 with the hanging edges 331 of the pair of upper end notches 33. The description of the upper first engagement state between the vertical frame 6 and the upper frame 3 can be used as a reference (the displacement of the vertical frame 5 toward the door tail becomes the displacement of the vertical frame 6 toward the door tail).

[0036] [B-2] Engagement of the intermediate vertical frame and the upper frame The front view shape of the upper end portion of the intermediate vertical frame 7 matches the front view shape (horizontal rectangle) of the upper intermediate cutout portion 34 of the upper frame 3. The upper end portion of the intermediate vertical frame 7 acts as an upper engaging portion, engaging with the upper intermediate cutout portion 34 from the depth direction to form an upper second engaging state. The depth width of the intermediate vertical frame 7 and the depth width of the upper frame 3 are approximately the same. The first visible edge 71 of the intermediate vertical frame 7 and the first visible edge 31 of the upper frame 3 form the same plane, and the second visible edge 72 of the intermediate vertical frame 7 and the second visible edge 32 of the upper frame 3 form the same plane.

[0037] In the upper second engagement state, the upper end edge 710 of the first visible edge 71 of the intermediate vertical frame 7 is close to or in contact with the upper edge 340 of the upper intermediate cutout 34 formed on the first visible edge 31 of the upper frame 3, the upper end portion of the end edge 712 of the first visible edge 71 is close to or in contact with the hanging edge 341 of the upper intermediate cutout 34 of the upper frame 3, and the upper end portion of the visible surface 70 of the intermediate vertical frame 7 is close to or in contact with the hanging edge 342 of the upper intermediate cutout 34 of the upper frame 3 (see Figure 3). In the upper second engagement state, the upper end edge 720 of the second visible edge 72 of the intermediate vertical frame 7 is close to or in contact with the upper edge 340 of the upper intermediate cutout 34 formed in the second visible edge 32 of the upper frame 3, the upper end portion of the end edge 722 of the second visible edge 72 is close to or in contact with the hanging edge 341 of the upper intermediate cutout 34 of the upper frame 3, and the upper end portion of the visible surface 70 of the intermediate vertical frame 7 is close to or in contact with the hanging edge 342 of the upper intermediate cutout 34 of the upper frame 3.

[0038] In the upper second engagement state, rotation of the upper end portion of the intermediate vertical frame 7 toward the door tail is restricted by one of the upper ends of the edge 712 of the first visible edge 71 and the edge 722 of the second visible edge 72 (the visible edge that is on the upper side in the orientation when the door body is assembled) contacting one of the hanging edges 341 of the pair of upper intermediate cutouts 34, and rotation of the upper end portion of the intermediate vertical frame 7 toward the door edge is restricted by the upper end portion of the depth surface 70 of the intermediate vertical frame 7 contacting the hanging edges 342 of the pair of upper intermediate cutouts 34. The displacement of the upper end of the intermediate vertical frame 7 toward the door edge is restricted by the upper end of the edge 712 of the first visible edge 71 and the upper end of the edge 722 of the second visible edge 72 contacting the hanging edges 341 of the pair of upper intermediate cutouts 34, and the displacement of the upper end of the intermediate vertical frame 7 toward the door edge is restricted by the upper end of the visible surface 70 of the intermediate vertical frame 7 contacting the hanging edges 342 of the pair of upper intermediate cutouts 34.

[0039] [C] Engagement of vertical frame and bottom frame [C-1] Engagement of the vertical frame and the lower frame The depth of the notch 431 formed at the longitudinal end of the first visible edge 41 of the lower frame 4 is slightly greater than the protruding dimensions of the projection pieces 53 and 63 of the vertical frames 5 and 6. The projection pieces 53 and 63, which protrude from the lower end of the vertical frames 5 and 6, act as lower engaging parts and engage with the lower end notch 43 formed at the longitudinal end of the upper surface 40 of the lower frame 4 from the depth direction, forming a lower first engaging state. The depth width of the vertical frames 5 and 6 and the depth width of the lower frame 4 are approximately the same. The first visible edges 51 and 61 of the vertical frames 5 and 6 and the first visible edge 41 of the lower frame 4 form the same plane, and the second visible edges 52 and 62 of the vertical frames 5 and 6 and the second visible edge 42 of the lower frame 4 form the same plane.

[0040] In the lower first engagement state, the projections 53 and 63 of the vertical frames 5 and 6 are located within the narrow portion 430 that extends in the depth direction at the longitudinal end of the upper surface 40 of the lower frame 4, and are close to or in contact with the longitudinal edge 400 of the upper surface 40 of the lower frame 4 (see Figures 4 and 5). In the lower first engagement state, inward rotation of the lower end portions of the vertical frames 5 and 6 is restricted by the projections 53 and 63 that protrude from the lower ends of the depth surfaces 50 and 60 of the vertical frames 5 and 6, contacting the longitudinal edge 400 of the upper surface 40 of the lower frame 4. In the door body according to this embodiment, a space is formed between the lower edge 14 of the first surface material 1 and the lower edge 24 of the second surface material 2, and the upper surface 40 of the lower frame 4 is visible from below. However, the lower end cutout portion 43 (narrow portion 430) formed on the upper surface 40 is narrow, and the projection pieces 53 and 63 are located in the narrow portion, so the cutout portion is not conspicuous.

[0041] [C-2] Engagement of the middle vertical frame and the lower frame The depth of the notch 441 formed in the longitudinal middle portion of the first visible edge 41 of the lower frame 4 is slightly greater than the protruding dimension of the projection 73 of the intermediate vertical frame 7. The projection 73, which protrudes from the lower end of the intermediate vertical frame 7, acts as a lower engaging portion and engages from the depth direction with the lower intermediate notch 44 formed in the longitudinal middle portion of the upper surface 40 of the lower frame 4, forming a lower second engaging state. The depth width of the intermediate vertical frame 7 and the depth width of the lower frame 4 are approximately the same. The first visible edge 71 of the intermediate vertical frame 7 and the first visible edge 41 of the lower frame 4 form the same plane, and the second visible edge 72 of the intermediate vertical frame 7 and the second visible edge 42 of the lower frame 4 form the same plane.

[0042] In the lower second engagement state, the projection 73 of the intermediate vertical frame 7 is located within the narrow portion 440 extending in the depth direction at the middle of the upper surface 40 of the lower frame 4, and is close to or in contact with the depth edge 440' that defines the narrow portion 440 (see Figures 3, 5, and 6). In the lower first engagement state, rotation of the lower end portion of the intermediate vertical frame 7 toward the door tail side and door leading side is restricted by the projection 73 protruding from the lower end of the depth surface 70 of the intermediate vertical frame 7 contacting the depth edge 440' of the narrow portion 440 of the lower intermediate cutout 44 formed on the upper surface 40 of the lower frame 4. In the door body according to this embodiment, a space is formed between the lower edge 14 of the first surface material 1 and the lower edge 24 of the second surface material 2, and the upper surface 40 of the lower frame 4 is visible from below. However, the lower intermediate cutout portion 44 (narrow portion 440) formed on the upper surface 40 is narrow, and a projection piece 73 is located in the narrow portion, so the cutout portion is not conspicuous.

[0043] [D] Method of manufacturing the door body [D-1] 1st process In the first step of the manufacturing method of the door body according to this embodiment, adhesive is applied to the second visible edges 32, 42, 52, 62, and 72 of the upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7 on the second visible surface 20 of the second surface material 2 which is placed horizontally on the floor surface, thereby bonding the second visible edges 32, 42, 52, 62, and 72 to the second visible surface 20. At the same time, the upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7 are assembled on the second visible surface 20 to form a flat frame assembly.

[0044] In the first step, the upper ends of the vertical frames 5 and 6 are upper engaging parts that engage with the upper end notches 33 from the inward direction (movement toward downward) to form an upper first engaging state. The projections 53 and 63 that protrude from the lower ends of the vertical frames 5 and 6 are lower engaging parts that engage with the lower end notches 43 from the inward direction (movement toward downward) to form a lower first engaging state. The upper end of the intermediate vertical frame 7 is upper engaging part that engages with the upper intermediate notches 34 from the inward direction (movement toward downward) to form an upper second engaging state. The projection 73 that protrudes from the lower end of the intermediate vertical frame 7 is lower engaging part that engages with the lower intermediate notches 44 from the inward direction (movement toward downward) to form a lower second engaging state.

[0045] In the frame assembly, the upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7 are placed on the second visible surface 20 with the second visible edges 32, 42, 52, 62, and 72 as the base. The upper end locking portions of the vertical frames 5 and 6 and the upper end notch portion 33 of the upper frame 3 are in a first upper locking state. The lower end locking portions (projections 53 and 63) of the vertical frames 5 and 6 and the lower end notch portion 43 of the lower frame 4 are in a first lower locking state. The upper end locking portion (projection 73) of the intermediate vertical frame 7 and the upper intermediate notch portion 34 of the upper frame 3 are in a second upper locking state. The lower end locking portion of the intermediate vertical frame 7 and the lower intermediate notch portion 44 of the lower frame 4 are in a second lower locking state.

[0046] Half of the upper surface 30 of the upper frame 3 (lower half) is close to or in contact with the upper edge (position of the rising edge) 23 of the second surface material 2, the lower end edge of the second visible edge 42 of the lower frame 4 is close to or in contact with the lower edge (position of the rising edge) 24 of the second surface material 2, half of the depth surface 50 of the vertical frame 5 (lower half) is close to or in contact with the depth edge (position of the rising edge) 21 of the second surface material 2, and half of the depth surface 60 of the vertical frame 6 (lower half) is close to or in contact with the depth edge (position of the rising edge) 22 of the second surface material 2.

[0047] [D-2] 2nd process In the second step, the first surface material 1 is placed over the frame assembly which is laid flat on the second visible surface 20 of the second surface material 2. Adhesive is applied to the first visible edge 31 of the upper frame 3, the first visible edge 41 of the lower frame 4, the first visible edges 51 and 61 of the left and right vertical frames 5 and 6, and the first visible edge 71 of the intermediate vertical frame 7 of the frame assembly which is laid flat. The first visible surface 10 of the first surface material 1 is then placed on the first visible edges 31, 41, 51, 61, and 71 of the upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7. The inner surface of the first visible surface 10 of the first surface material 1 is then bonded to the first visible edges 31, 41, 51, 61, and 71 of the upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7 with adhesive, forming the door body (before adhesive hardening) 8'.

[0048] In the door body (before adhesive hardening) 8', half of the upper surface 30 of the upper frame 3 is close to or in contact with the upper edge (hanging edge) 13 of the first surface material 1, the lower edge of the first visible edge 41 of the lower frame 4 is close to or in contact with the lower edge (hanging edge) 14 of the first surface material 1, half of the depth surface 50 of the vertical frame 5 is close to or in contact with the depth edge (hanging edge) 11 of the first surface material 1, and half of the depth surface 60 of the vertical frame 6 is close to or in contact with the depth edge (hanging edge) 12 of the first surface material 1. In one embodiment, before the third step, the door body is assembled with the facing surface 50 of the vertical frame 5 in close contact with the facing edge 21 of the second surface material 2 and the facing edge 11 of the first surface material 1, and the facing surface 60 of the vertical frame 6 in close contact with the facing edge 22 of the second surface material 2 and the facing edge 12 of the first surface material 1.

[0049] [D-3] 3rd process The third step is to cure the adhesive in the door body (before adhesive curing) 8' to obtain the door body (after adhesive curing) 8. As shown in Figure 13, the third step consists of transporting the door body (before adhesive curing) 8' to the hot press machine P using a roller conveyor R, which is an example of a transport means; heat-pressing the door body (before adhesive curing) 8' in the hot press machine P to cure the adhesive; and transporting the door body (after adhesive curing) 8 out using the roller conveyor R. By using the hot press machine P, the curing time of the adhesive can be shortened compared to when the adhesive is allowed to air dry. The third step also includes cases where a person places the door body (before adhesive curing) 8' on a trolley or the like and carries it to the hot press machine P (at this time, the frame material is prevented from tipping over), and a person carries the door body (after adhesive curing) 8 to the storage location.

[0050] [D-4] Preventing frame material from falling over In this embodiment, in the first, second, and third steps, the inward tilting of the vertical frames 5 and 6 is restricted by the first engagement state (upper first engagement state, lower first engagement state), the outward tilting of the vertical frames 5 and 6 is restricted by the pair of protruding edges (21, 22) of the second surface material 2 and the pair of protruding edges (11, 12) of the first surface material, and the bidirectional tilting of the intermediate vertical frame is restricted by the second engagement state (upper second engagement state, lower second engagement state). In particular, in the third step, when the door body (before adhesive curing) 8' is transported by the roller conveyor R, vibration acts on the door body (before adhesive curing) 8', which may cause the frame material to shift or fall over. The prevention of frame material falling over will be described in detail below.

[0051] The upper frame 3, lower frame 4, vertical frames 5 and 6, and intermediate vertical frame 7 all have a U-shape in cross-section. When placed on the second visible surface 20 of the second surface material 2 in a horizontal position, the height dimension when standing upright with one visible side as the base is greater than the base, resulting in an unstable (prone to tipping) position. However, in this embodiment, tipping and displacement of the frame materials (upper frame 3, lower frame 4, vertical frames 5 and 6, intermediate vertical frame 7) during the manufacturing process (especially the third process) are prevented by preventing the frame materials (upper frame 3, lower frame 4, vertical frames 5 and 6, intermediate vertical frame 7) placed on the second visible surface 20 of the second surface material 2.

[0052] The upper frame 3 is positioned upright on the second surface surface 20 of the second surface material 2, with the second visible edge 32 attached to the second visible surface 20 of the second surface material 2 by adhesive, using the second visible edge 32 as its base. In this position, the upper edge 23 of the second surface material 2 (which rises vertically in the horizontal position of the second surface material 2) is in contact with or close to the lower half of the upper surface 30 of the upper frame 3, preventing the upper frame 3 from tilting outward. The inward tilting of the upper frame 3 is restricted by the upper engagement state (upper first engagement state, upper second engagement state) with the vertical frames 5, 6 and the intermediate vertical frame 7.

[0053] The lower frame 4 is positioned upright on the second surface surface 20 of the second surface material 2 with its second visible edge 42 as its base, with the second visible edge 42 bonded to the second visible surface 20 of the second surface material 2 by adhesive. In this position, the lower edge 24 of the second surface material 2 (which rises vertically in the horizontal position of the second surface material 2) is in contact with or close to the edge of the second visible edge 42 (base) of the lower frame 4, preventing the lower frame 4 from tilting outward. The inward tilting of the lower frame 4 is restricted by the lower engagement state (lower first engagement state, lower second engagement state) with the vertical frames 5, 6 and the intermediate vertical frame 7.

[0054] The vertical frames 5 and 6 are positioned upright on the second surface surface 20 of the second surface material 2, with their second visible edges 52 and 62 bonded to the second visible surface 20 of the second surface material 2 by adhesive. In this position, the lower halves of the visible surfaces 50 and 60 of the vertical frames 5 and 6 are in contact with or close to the visible edges 21 and 22 of the second surface material 2 (which rise vertically in the horizontal position of the second surface material 2), preventing the vertical frames 5 and 6 from tilting outward. The inward tilting of the vertical frames 5 and 6 is restricted by the upper first engagement state with the upper end notch 33 of the upper frame 3 and the lower first engagement state with the lower end notch 43 of the lower frame 4.

[0055] The intermediate vertical frame 7 is positioned upright on the second surface surface 20 of the second surface material 2 with its second visible edge 72 as its base, with the second visible edge 72 being bonded to the second visible surface 20 of the second surface material 2 by adhesive. In this position, tilting of the intermediate vertical frame 7 to either side (door tail side and door leading side) is restricted by the upper second engagement state with the upper intermediate notch 34 of the upper frame 3 and the lower second engagement state with the lower intermediate notch 44 of the lower frame 4.

[0056] [E] Other embodiments Referring to Figures 10 to 12, the door structure and door manufacturing method according to other embodiments will be described. In the other embodiments, the configuration of the upper engagement state (upper first engagement state, upper second engagement state) between the upper frame 3 and the vertical frames 5, 6 and intermediate vertical frame 7 is the same as in the previously described embodiments, and the previously described upper engagement state and door manufacturing method can be referred to. The following mainly describes the differences.

[0057] [E-1] Lower frame The lower frame 4' is a long member extending in the width direction of the door body, and has a length (visible dimension) that is approximately corresponding to the door width (visible width) and a depth that is approximately corresponding to the thickness (depth width) of the door body. As shown in Figure 11, the lower frame 4' is formed in a U-shape in cross-section from a lower surface 40', a first visible edge 41' that rises vertically from one end of the lower surface 40' in the depth direction, and a second visible edge 42' that rises vertically from the other end of the lower surface 40' in the depth direction. When the door body is assembled, the lower edge 14' of the first surface material 1 and the lower edge 24' of the second surface material 2 are in close contact with the lower surface 40' of the lower frame 4'.

[0058] [E-1-1] Lower end cutout At both ends of the lower frame 4 in the longitudinal direction, lower end notches 43' are formed opposite each other at both ends of the first visible edge 41' and the second visible edge 42' in the longitudinal direction. The lower end notches 43' are rectangular in shape when viewed from the front, and are defined by the lower edge of the long side and the vertical edge of the short side. The visible width of the lower end notches 43' is approximately the same as, or greater than, the visible width of the vertical frames 5 and 6.

[0059] [E-1-2] Lower intermediate cutout In the lower frame 4', a lower intermediate notch 44' is formed opposite to the first visible edge 41' and the second visible edge 42' at predetermined intermediate points in the longitudinal direction. The lower intermediate notch 44' is rectangular in shape when viewed from the front, and is defined by the lower edge of the long side and the left and right vertical edges of the short side. The visible width of the lower intermediate notch 44' is approximately the same as or greater than the visible width of the intermediate vertical frame 7. In this embodiment, the visible width of the lower end notch 43' and the visible width of the lower intermediate notch 44' are approximately the same.

[0060] [E-2] Lower engagement state [E-2-1] Lower first engagement state The lower ends of the vertical frames 5 and 6 (the lower ends of the facing surfaces 50 and 60, the first facing edges 51 and 61, and the second facing edges 52 and 62) are lower end engagement portions that engage with the lower end cutout portion 43' of the lower frame 4', and the lower ends of the vertical frames 5 and 6 engage with the lower end cutout portion 43' of the lower frame 4' from the facing direction to form the lower first engagement state.

[0061] [E-2-2] Lower second engagement state The lower end portion of the intermediate vertical frame 7 (the lower end portion of the facing surface 70, the first facing edge 71, and the second facing edge 72) engages with the lower intermediate notch 44' of the lower frame 4', forming a lower second engagement state when the lower end portion of the intermediate vertical frame 7 engages with the lower intermediate notch 44' of the lower frame 4' from the facing direction.

[0062] [F] Other embodiments Referring to Figures 14 to 17, a door structure according to another embodiment will be described. In this other embodiment, the configuration of the upper engagement state (upper first engagement state, upper second engagement state) between the upper frame 3 and the vertical frames 5, 6 and the intermediate vertical frame 7, and the lower engagement state (lower second engagement state) between the lower frame 4 and the intermediate vertical frame 7 are the same as in the previously described embodiment, and the previously described method can be used to refer to the upper engagement state, the lower second engagement state, and the method of manufacturing the door. The following will mainly describe the differences.

[0063] [F-1] Surface material As shown in Figures 14 and 15, the first surface material 1 consists of a first visible surface 10 that forms the first surface of the door body, left and right bent edges 11 and 12 formed at right angles at both ends in the width direction of the first visible surface 10, and an upper edge 13 formed at right angles at the upper end of the first visible surface 10, but no bent edge is formed at the lower end of the first visible surface 10. The second surface material 2 consists of a second visible surface 20 that forms the second surface of the door body, left and right bent edges 21 and 22 formed at right angles at both ends in the width direction of the second visible surface 20, and an upper edge 23 formed at right angles at the upper end of the second visible surface 20, but no bent edge is formed at the lower end of the second visible surface 20. The bent edges 14 and 24 at the lower ends of the first and second visible surfaces 10 and 20 (see Figure 6) serve to prevent leakage of adhesive in the adhesive bonding method and to restrict the movement of the lower frame 4 before the adhesive hardens. However, other methods (welding and screw fastening methods) do not have such bent edges, resulting in a difference in the appearance of the door body compared to other methods. In the embodiments shown in Figures 14 and 15, by not providing bent edges at the lower ends of the first and second visible surfaces 10 and 20, the appearance of the surface material in the adhesive bonding method can be made consistent with other methods.

[0064] [F-2] Lower frame The lower frame 4 is a long member extending in the width direction of the door body, and has a length (visible dimension) that is approximately corresponding to the door width (visible width) and a depth that is approximately corresponding to the thickness (depth width) of the door body. As shown in Figure 16, the lower frame 4 is formed in a U-shape in cross-section from an upper surface 40, a first visible edge 41 hanging down from one end of the upper surface 40 in the depth direction, and a second visible edge 42 hanging down from the other end of the upper surface 40 in the depth direction.

[0065] Lower end notches 43'' are formed at both ends in the longitudinal direction of the lower frame 4. The lower end notches 43'' consist of a narrow portion 430'' that extends in the depth direction from the longitudinal end of the upper surface 40 of the lower frame 4, and a notch 431'' at the upper end of the longitudinal end of the first visible edge 41, with the narrow portion 430'' and the notch 431'' being continuous. The visible width of the notch 431'' is greater than the visible width of the narrow portion 430''.

[0066] [F-3] Vertical Frame The vertical frames 5 and 6 are elongated members that extend in the height direction of the door body, and have a length (height) that is approximately corresponding to the door height and a depth (depth) that is approximately corresponding to the thickness (depth) of the door body. The left and right vertical frames 5 and 6 are symmetrical and have essentially the same shape. As shown in Figures 14 and 17, the height of the vertical frames 5 and 6 is lower than the total height of the door body, the upper ends of the vertical frames 5 and 6 engage with the upper frame 3, and the lower ends of the vertical frames 5 and 6 engage with the lower frame 4.

[0067] As shown in Figure 17, the vertical frame 5, which is the door-side vertical frame, is formed in a U-shape in cross-section from a depth surface 50, a first facing edge 51 extending in the facing direction from one end of the depth surface 50 in the depth direction, and a second facing edge 52 extending in the facing direction from the other end of the depth surface 50 in the depth direction. A lower engaging piece 53'' is projected from the lower end edge 501 of the depth surface 50 of the vertical frame 5, and the lower engaging piece 53'' protrudes below the lower end edge 501 of the depth surface 50, the lower end edge 511 of the first facing edge 51, and the lower end edge 521 of the second facing edge 52. The lower engaging piece 53'' has an L-shape in side view from a hanging piece 530'' and a bent piece 531'' at the lower end of the hanging piece 530''. The bent portion 531'' of the lower engaging piece 53'' extends toward the inside of the vertical frame 5 (the side from which the first visible edge 51 and the second visible edge 52 extend from the visible surface 50). The lower engaging piece 53'' forms the lower engaging portion. In this embodiment, the angle between the hanging piece 530'' and the bent portion 531'' is approximately 90 degrees, but the bent portion 531'' may extend at an angle of 90 degrees or more relative to the hanging piece 530''.

[0068] The vertical frame 6, which is the door-end vertical frame, is formed in a U-shape in cross-section from a depth surface 60, a first facing edge 61 extending in the facing direction from one end of the depth surface 60 in the depth direction, and a second facing edge 62 extending in the facing direction from the other end of the depth surface 60 in the depth direction. A lower engaging piece 63'' is projected from the lower end edge 601 of the depth surface 60 of the vertical frame 6, and the lower engaging piece 63'' protrudes below the lower end edge 601 of the depth surface 60, the lower end edge 611 of the first facing edge 61, and the lower end edge 621 of the second facing edge 62. The lower engaging piece 63'' has an L-shape in side view from a hanging piece 630'' and a bent piece 631'' at the lower end of the hanging piece 630''. The bent portion 561'' of the lower engaging piece 63'' extends toward the inside of the vertical frame 6 (the side from which the first visible edge 61 and the second visible edge 62 extend from the visible surface 60). The lower engaging piece 63'' forms the lower engaging portion. In this embodiment, the angle between the hanging piece 630'' and the bent portion 631'' is approximately 90 degrees, but the bent portion 631'' may extend at an angle of 90 degrees or more relative to the hanging piece 630''.

[0069] [F-4] Lower first engagement state Lower engaging pieces 53'' and 63'', which protrude from the lower ends of vertical frames 5 and 6, form lower end engaging portions that engage with the lower end notches 43'' of the lower frame 4. The notches 431'' of the lower end notches 43'' correspond to the side or cross-sectional shapes of the lower engaging pieces 53'' and 63'', allowing the lower engaging pieces 53'' and 63'' to be received from the inside. The height dimensions of the vertical pieces 530'' and 630'' of the lower engaging pieces 53'' and 63'' are approximately the same as the plate thickness of the upper surface 40 of the lower frame 4. The lower engaging pieces 53'' and 63'' of vertical frames 5 and 6 engage with the lower end notches 43'' of the lower frame 4 from the inside, forming a lower first engagement state. In the first lower engagement state, the bent pieces 531'' and 631'' of the lower engagement pieces 53'' and 63'' are locked to the widthwise (lengthwise) end of the upper surface 40 of the lower frame 4 (see Figure 15). Also, the lower end edge 511 of the first visible edge 51 and the lower end edge 521 of the second visible edge 52 abut against both ends of the upper surface 40 of the lower frame 4 in the depth direction, and one end of the upper surface 40 in the widthwise (lengthwise) direction is sandwiched between the lower end edge 511 of the first visible edge 51 and the lower end edge 521 of the second visible edge 52 and the bent piece 531'' of the lower engagement piece 53''. Similarly, the other end of the upper surface 40 in the width direction (length direction) is sandwiched between the lower edge 611 of the first visible edge 61, the lower edge 621 of the second visible edge 62, and the bent piece 631'' of the lower engaging piece 63''.

[0070] As shown in Figure 6, in the embodiment in which the lower ends of the first visible surface 10 and the second visible surface 20 are provided with bent edges 14 and 24, these bent edges 14 and 24 also function as restricting edges in the bonding method of the door body, preventing the lower frame 4 from moving away from or detaching from the lower ends of the first visible surface 10 and the second visible surface 20 (downward) before the adhesive hardens. However, in this embodiment, as shown in Figures 14 and 15, the lower ends of the first visible surface 10 and the second visible surface 20 are not provided with bent edges 14 and 24. In the lower first engagement state in this embodiment, the bent pieces 531'' and 631'' of the lower engagement pieces 53'' and 63'' are locked to the widthwise (lengthwise) ends of the upper surface 40 of the lower frame 4. Therefore, in a frame assembly that is laid flat, movement of the lower frame 4 away from or detached from the lower ends of the first visible surface 10 and the second visible surface 20 (downward) is restricted by the bent pieces 531'' and 631'' being locked to the widthwise (lengthwise) ends of the upper surface 40 of the lower frame 4. [Explanation of Symbols]

[0071] 1 1st surface material 10 1st report page 11. Inserts (a pair of first inserts) 12. Inserts (a pair of first inserts) 2 Second surface material 20 2nd page 21. Insert (a pair of second inserts) 22. Insert (a pair of second inserts) 3. Top frame (horizontal frame) 30 Top side 31 Mitsukebe 32 Mitsukebe 33. Upper end notch (upper end first engagement state) 34 Upper intermediate notch (upper end second engagement state) 4. Bottom frame (horizontal frame) 40 Top side 41 Mitsukebe 42 Mitsukebe 43 Lower end notch (lower end first engagement state) 430 Narrow part 431 Notch 44 Lower intermediate notch (lower end second engagement state) 440 Narrow part 441 Notch 5 Vertical Frames 50 View 51 First lookout edge 52 Second Mitsuke area 53 Projection piece (lower engaging piece, lower end in first engaged state) 53'' Lower engaging piece (lower end first engaging state) 530´´ hanging piece 531´´ bent piece 6 Vertical Frames 60 Front view 61 First Lookout Side 62 Second Mitsuke area 63. Projection piece (lower engaging piece, lower end in first engaged state) 63'' Lower engaging piece (lower end first engaging state) 630´´ hanging piece 631´´ Bent piece 7. Intermediate vertical frame 70 View 71 First Lookout Side 72 Second Mitsuke area 73. Projection piece (lower end in second engagement state) P Hot press machine (heat press means)

Claims

1. In a door structure comprising a frame assembly made up of upper and lower horizontal frames, left and right vertical frames, and one or more intermediate vertical frames, End notches are formed at the longitudinal ends of the horizontal frame, and engagement portions are formed at the longitudinal ends of the left and right vertical frames, which engage with the end notches from the depth direction to form a first engagement state. An intermediate notch is formed in the middle of the length of the horizontal frame, and an engaging portion is formed at the end of the intermediate vertical frame in the length direction, which engages with the intermediate notch from the depth direction to form a second engaged state. The first engagement state is such that, when the frame assembly is laid flat, the inward tilting of the vertical frame is restricted. The second engagement state is such that, when the frame assembly is laid flat, the tilting of the intermediate vertical frame in both directions is restricted. Door structure.

2. The aforementioned horizontal frame, the upper frame, comprises a top surface and a pair of visible edges. The aforementioned vertical frame and the aforementioned intermediate vertical frame each comprise a face surface and a pair of facing edges, The end notches and the intermediate notches are upper notches formed opposite to a pair of visible edges of the upper frame. The upper ends of the pair of visible edges of the vertical frame and the intermediate vertical frame engage with the upper notch from the depth direction, forming an upper first engagement state and an upper second engagement state. The door structure according to claim 1.

3. The aforementioned horizontal frame, the lower frame, comprises a top surface and a pair of visible edges. The aforementioned vertical frame and the aforementioned intermediate vertical frame each comprise a face surface and a pair of facing edges, The end notch and the intermediate notch are lower notches formed continuously on the upper surface and the upper end of at least one of the visible edges of the lower frame. The projections extending from the lower ends of the depth surfaces of the vertical frame and the intermediate vertical frame engage with the lower notch from the depth direction, forming a lower first engagement state and a lower second engagement state. The door structure according to claim 2.

4. The upper cutout is wider in the visible direction, and the lower cutout is narrower in the visible direction. The door structure according to claim 3.

5. The aforementioned horizontal frame, the lower frame, comprises a top surface and a pair of visible edges. The aforementioned vertical frame comprises a front surface and a pair of front edges, The end cutout is a lower cutout formed continuously on the upper surface of the lower frame and the upper end of at least one of the visible edges. A lower engaging piece protruding from the lower end of the depth surface of the vertical frame engages with the lower notch from the depth direction, forming a lower first engaging state. The door structure according to claim 1.

6. The lower engaging piece consists of a hanging piece and a bent piece at the lower end of the hanging piece. In the lower first engagement state, the bent portion of the lower engagement piece is locked to the upper surface of the lower frame. The door structure according to claim 5.

7. The aforementioned door structure includes a first surface material and a second surface material. The first surface material comprises a first visible surface that forms the first surface portion of the door body, and a pair of first visible edges. The second surface material comprises a second visible surface that forms the second surface portion of the door body, and a pair of second visible edges. The first visible surface and the second visible surface are bonded to the visible edge of the frame assembly, and the first and second deep edges are in contact with the outer surface of the deep surface of the vertical frame. The door structure according to any one of claims 1 to 6.

8. A method for manufacturing a door body from multiple frame materials including upper and lower horizontal frames and three or more vertical frames, a first surface material, and a second surface material, The frame material comprises a face surface and a pair of visible edges, The first surface material comprises a first visible surface that forms the first surface portion of the door body, and a pair of first visible edges. The second surface material comprises a second facing surface that forms the second surface portion of the door body, and a pair of second facing edges. A first step is to assemble the frame material by applying adhesive between the first visible surface of the first surface material in a horizontal position and one visible edge of the frame material, thereby forming a flat-lying frame assembly, A second step involves applying adhesive between the second visible surface of the second surface material and the other visible edge of the frame material, and covering the frame assembly with the second surface material. A third step involves curing the adhesive to bond the frame assembly to the first surface material and the second surface material, It consists of, In the first step described above, Multiple notches are formed along the length of the horizontal frame, and engaging portions formed at the ends of the vertical frame along the length are engaged with the notches from the depth direction to constitute an engaged state. In the first, second, and third steps, The aforementioned engagement state restricts the tilting of the vertical frame. A method for manufacturing a door panel.

9. The aforementioned three or more vertical frames consist of left and right vertical frames and one or more intermediate vertical frames. In the first step described above, End notches are formed at the longitudinal ends of the horizontal frame, and engaging portions formed at the longitudinal ends of the left and right vertical frames are engaged with the end notches from the depth direction to constitute a first engaged state. An intermediate notch is formed in the middle of the length of the horizontal frame, and an engaging portion formed at the end of the intermediate vertical frame in the length direction is engaged with the intermediate notch from the depth direction to constitute a second engaged state. In the first, second, and third steps, The aforementioned first engagement state restricts the inward tilting of the vertical frame. The first and second edges restrict the outward tilting of the vertical frame. The second engagement state restricts the tilting of the intermediate vertical frame in both directions. The method for manufacturing a door body according to claim 8.

10. The aforementioned horizontal frames, the upper frame and the lower frame, each have a top surface and a pair of visible edges. The end notch consists of an upper end notch formed opposite to a pair of visible edges of the upper frame, and a lower end notch formed continuously on the upper surface of the lower frame and the upper end of at least one of the visible edges. The upper end portion of the vertical frame serves as an upper engaging portion, engaging with the upper end notch from the depth direction to form an upper first engaging state. The projection piece extending from the lower end of the depth surface of the vertical frame serves as a lower engaging portion, engaging with the lower end notch from the depth direction to form a lower first engaging state. The aforementioned intermediate cutout consists of an upper intermediate cutout formed opposite to a pair of visible edges of the upper frame, and a lower intermediate cutout formed continuously on the upper surface of the lower frame and the upper end of at least one of its visible edges. The upper end portion of the intermediate vertical frame serves as an upper engaging portion, engaging with the upper intermediate notch from the depth direction to form an upper second engaging state. The projection piece extending from the lower end of the depth surface of the intermediate vertical frame serves as a lower engaging portion, engaging with the lower intermediate notch from the depth direction to form a lower second engaging state. A method for manufacturing a door body according to claim 9.

11. The third step is, A process of transporting an assembly consisting of multiple frame members, a first surface material, and a second surface material to a heat pressurizing means, The process of curing the adhesive using the aforementioned heat and pressure means, A method for manufacturing a door body according to any one of claims 8 to 10, including the following:

Images