Shoji screens and their manufacturing methods

Abstract

To provide a sash which allows for improved manufacturing efficiency through more efficient processing of face bar ends, and a sash manufacturing method.SOLUTION: A sash 2 has a pair of face bars 20, 20 that are formed of a steel plate and disposed so as to face each other, and a core material disposed between the pair of face bars 20, 20. The face bar 20 has a surface part 31 formed into a rectangle shape and folded parts 33 that are formed at least on one side of the surface part 31 and folded to the opposing face bar 20 side. The folded parts 33 are formed at a plurality of positions along the extending direction of one side. Tips of the folded parts 33 of the pair of the face bars 20, 20 are separated away from each other.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a shoji screen and a method for manufacturing a shoji screen. [Background technology]

[0002] Conventionally, a shoji screen, such as a double door, has been known to have a configuration comprising a steel surface member placed on the front side, a steel backing member placed on the back side, and a core member placed between the surface member and the backing member. The widthwise ends of the surface member and the backing member are bent at approximately right angles over their entire length in the vertical direction, and are welded together in a butted state (see, for example, Patent Document 1 below). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-178735 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, it is necessary to bend the widthwise ends of the front and back materials over the entire length in the vertical direction, which poses a problem of time-consuming processing.

[0005] The present disclosure has been made in consideration of the above circumstances, and provides a shoji screen and a method for manufacturing a shoji screen that can improve the manufacturing efficiency of processing the ends of face materials. [Means for solving the problem]

[0006] A shoji screen according to one aspect of the present disclosure comprises a pair of face panels formed from steel plates and arranged opposite each other, and a core material arranged between the pair of face panels, wherein the face panels have a rectangular face portion and a bent portion formed on at least one side of the face portion and bent towards the opposing face panel, the bent portion being formed at multiple locations along the extension direction of the one side, and the tips of the bent portions of the pair of face panels being spaced apart from each other. [Brief explanation of the drawings]

[0007] [Figure 1] This is a front view of a fitting equipped with a shoji screen, viewed from the outside. [Figure 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Figure 3] FIG. [Figure 4] FIG. 2 is an enlarged view showing the configuration of the folding portion of the shoji screen. [Figure 5] 10A and 10B are diagrams illustrating a manufacturing method of a shoji screen. [Figure 6] FIG. 6 is a diagram illustrating a manufacturing method of a shoji screen, showing a step subsequent to that shown in FIG. 5. [Figure 7] 10 is a diagram illustrating a manufacturing method of a shoji screen, and is an enlarged view of a connection portion. FIG. [Figure 8] FIG. 10 is an enlarged view showing the configuration of the groove portion of the connecting portion of the shoji screen. [Figure 9] 7 is a diagram for explaining the manufacturing method of a shoji screen, showing the process subsequent to that shown in FIG. 6. FIG. [Figure 10] 10 is a diagram for explaining the manufacturing method of a shoji screen, showing the subsequent step of FIG. 9. [Figure 11] 10 is an enlarged view showing the configuration of the end surface of the tip of the folding portion of the shoji screen. FIG. [Figure 12] 10 is a diagram illustrating the manufacturing method of a shoji screen, showing the subsequent step of FIG. [Figure 13] 12A to 12C are diagrams illustrating the manufacturing method of a shoji screen. DETAILED DESCRIPTION OF THE INVENTION

[0008] A fitting equipped with a shoji screen according to one embodiment will be described below with reference to the drawings. The following embodiment illustrates one aspect of the present disclosure and does not limit the present disclosure. Any modification can be made within the scope of the technical concept of the present disclosure. In the following description, the horizontal direction connecting the outdoor side (the +Y side shown in FIG. 2, etc.) and the indoor side (the -Y side shown in FIG. 2, etc.) is referred to as the indoor-outdoor direction (the direction of arrow Y in the figure). The horizontal direction perpendicular to the indoor-outdoor direction is referred to as the width direction (the direction of arrow X in the figure). The direction perpendicular to the indoor-outdoor direction and the width direction is referred to as the up-down direction (the direction of arrow Z in the figure). In each component, the side away from the center in the indoor-outdoor direction and the width direction is sometimes referred to as the outside, and the side toward the center is sometimes referred to as the inside.

[0009] 1, the fixture 100 is a parent-child door. The fixture 100 comprises a frame 1, a child door 2, and a parent door 3.

[0010] The frame body 1 has an upper frame 11, a lower frame 12, and a pair of vertical frames 13, 13. The upper frame 11 and the lower frame 12 extend in the width direction. The vertical frame 13 extends in the up-down direction. The upper end of the vertical frame 13 is connected to the upper frame 11. The lower end of the vertical frame 13 is connected to the lower frame 12.

[0011] The child door 2 and the main door 3 are arranged adjacent to each other in the width direction. The child door 2 and the main door 3 are arranged inside the frame 1. The length of the child door 2 in the width direction is shorter than the length of the main door 3 in the width direction.

[0012] The structure of the sub-door 2 will be described in detail. As shown in Fig. 2, the sub-door 2 comprises a surface member 21, a backing member 22, a core member 23, and a heat insulating member 24. The surface member 21 and the backing member 22 are arranged opposite each other in the indoor / outdoor direction. The surface member 21 is arranged on the outdoor side. The surface member 21 and the backing member 22 are sometimes collectively referred to as the surface member 20.

[0013] The face material 20 is formed of a steel plate. As shown in FIG. 3, the face material 20 has a face portion 31, an end face portion 32, and a bent portion 33.

[0014] The surface portion 31 is formed in a plate shape. The plate surface of the surface portion 31 faces the indoor / outdoor direction. The surface portion 31 is rectangular. The surface portion 31 has a rectangular shape that is long in the vertical direction.

[0015] The end surface portions 32 are formed on the edges 31a, 31a of a pair of short sides of the surface portion 31 and on the edge 31b of one long side. The end surface portions 32 are configured by being bent at approximately right angles from the edges 31a, 31b of the surface portion 31. The end surface portion 32 formed on the edge 31a is formed over approximately the entire length in the width direction, which is the extension direction of the short sides. The end surface portion 32 formed on the edge 31b is formed over approximately the entire length in the up-down direction, which is the extension direction of the long sides.

[0016] The other long side of the surface portion 31 where the end surface portion 32 is not provided is defined as the edge portion 31d. The bent portion 33 is configured by being bent at a substantially right angle from the edge portion 31d of the surface portion 31 toward the opposing surface material 20. As shown in FIG. 2, the edge portion 31d where the bent portion 33 is formed is the edge portion on the door tip side of the sub-door 2.

[0017] 3, the bent portions 33 are formed at multiple locations along the vertical direction, which is the extending direction of the edge portion 31d. The bent portions 33 are formed at three locations on the edge portion 31d: the top, bottom, and approximately the center in the vertical direction.

[0018] As shown in FIG. 4, the left-right direction when the bent portion 33 is viewed from the front is the width direction of the bent portion 33. The width direction of the bent portion 33 formed at the edge portion 31d is the up-down direction. At the base end portion 33a of the bent portion 33 bent from the surface portion 31, recesses 33b that are recessed inward in the width direction are formed on both sides in the width direction of the bent portion 33. The recesses 33b are approximately semicircular. The width direction length A1 of the bent portion 33 is preferably 5 mm to 100 mm, but can be set appropriately.

[0019] The tip end 33c of the bent portion 33 formed on the front surface member 21 and the tip end 33c of the bent portion 33 formed on the back surface member 22 are spaced apart from each other in the indoor / outdoor direction.

[0020] 2, the core material 23 is disposed on both sides in the width direction between the front surface material 21 and the back surface material 22. The core material 23 is disposed over substantially the entire length in the up-down direction of the sub-door 2. In a cross section along the width direction and the indoor-outdoor direction, the core material 23 has a C-shape that opens inward in the width direction.

[0021] The core material 23 has a first plate portion 23a and a pair of second plate portions 23b. The first plate portion 23a is formed in a plate shape. The plate surface of the first plate portion 23a faces the width direction. The second plate portions 23b extend inward in the width direction from both ends of the first plate portion 23a in the indoor / outdoor direction. The second plate portions 23b are formed in a plate shape. The plate surfaces of the second plate portions 23b face the indoor / outdoor direction.

[0022] The heat insulating material 24 is disposed between the front surface material 21 and the back surface material 22, and is located more inward in the width direction than the core material 23.

[0023] A method for manufacturing the sub-door 2 will now be described. The sub-door 2 is manufactured using a processing device (not shown). As shown in FIG. 5, a steel plate material panel 40 is prepared. The material panel 40 is cut into the shape of a pre-bending panel 41 shown in FIG. 6.

[0024] The bent front panel 41 has a pair of flat plate portions 42, 42 and a connecting portion 43. The flat plate portion 42 is rectangular. The pair of flat plate portions 42, 42 are arranged with their long sides, i.e., their edge portions 31d, adjacent to each other. The connecting portion 43 connects the edge portions 31d of the pair of flat plate portions 42, 42 to each other. A plurality of connecting portions 43 are formed along the extension direction of the edge portion 31d. The connecting portion 43 is arranged on both ends and in the center of the edge portion 31d. The direction in which the pair of flat plate portions 42, 42 are adjacent to each other is defined as the arrangement direction (the direction of arrow B in the figure). The direction along the edge portion 31d is defined as the width direction of the connecting portion 43 (the direction of arrow C in the figure).

[0025] 7, recesses 43b recessed inward in the width direction are formed on both sides in the width direction of the base end 43a of the connecting portion 43. The recesses 43b are substantially semicircular.

[0026] A groove 44 is formed in the center in the arrangement direction of the connecting portions 43. The groove 44 is formed over substantially the entire length of the connecting portions 43 in the width direction.

[0027] 8, grooves 44 are formed on one surface 43c of connecting portion 43. It is preferable that surface 43c on which grooves 44 are formed be formed on a surface that faces outward when folded in a later process.

[0028] The groove 44 is recessed from the surface 43c toward the other surface 43d of the connecting portion 43. The groove 44 has a V-shape in cross section perpendicular to the width direction of the connecting portion 43.

[0029] As shown in FIG. 9, the other three sides of the flat plate portion 42 are bent at approximately right angles to form the end surface portions 32.

[0030] The connecting portion 43 is cut along the groove portion 44 shown in Figures 7 and 8. As shown in Figure 10, the connecting portion 43 is separated into two, and the half connecting portion 45 remains connected to each of the face materials 20, and the pair of face materials 20 is separated.

[0031] 11 shows the folded portion 33 in which the half-joint portion 45 is bent in a later process, but the configuration of the end surface of the tip of the half-joint portion 45 is the same as the configuration of the end surface 33d of the tip portion 33c of the folded portion 33. Because the groove portion 44 is formed in a V-shape, when cut, as shown in FIG. 11, the end surface 33d of the tip portion 33c of the folded portion 33 has a sheared surface portion 34 and a fractured surface portion 35. The sheared surface portion 34 is located on the side of the surface 43c where the groove portion 44 was formed. The fractured surface portion 35 is located on the side of the surface 43d opposite the groove portion 44.

[0032] The sheared surface portion 34 is formed with streaks in a direction perpendicular to the plate surface of the face material 20. The sheared surface portion 34 has multiple streaks that extend in the plate thickness direction. The fractured surface portion 35 has multiple small irregularities. The sheared surface portion 34 is the portion where the groove portion 44 was originally formed, and is created when excessive force is not applied when cutting the mechanically formed groove portion 44. The fractured surface portion 35 is the portion closer to the surface 43d than the groove portion 44 where the groove portion 44 was not originally formed, and is created when excessive force is applied when cutting.

[0033] As shown in Fig. 12, adhesive 46 is applied to the inner surface 20a of the face material 20. On the inner surface 20a of one face material 20A, core materials 23 are placed on both sides in the width direction, and insulating materials 24 are placed inside the core materials 23 in the width direction.

[0034] As shown in Figure 13, half connecting portion 45 of face material 20A is bent at edge 31d at a substantially right angle to form bent portion 33. Half connecting portion 45 of the other face material 20B is also bent at edge 31d at a substantially right angle to form bent portion 33. As shown in Figure 7, when bending, connecting portion 43 may bulge outward in the width direction due to the influence of the plate thickness and hardness of connecting portion 43, but because base end 43a of connecting portion 43 has recessed portion 43b that is recessed inward in the width direction of connecting portion 43, it can be bent at a substantially right angle.

[0035] Face material 20B is arranged to face face material 20A with core material 23 and heat insulating material 24 sandwiched therebetween. Folded portions 33 of face materials 20A and 20B are arranged along first plate portion 23a of core material 23. The widthwise position of core material 23 is determined by folded portions 33 of face materials 20A and 20B until adhesive 46 hardens.

[0036] In the fitting 100 configured in this manner, the bending portions 33 are formed at three locations spaced apart in the vertical direction, which is the extension direction of the edge portion 31d of the panel 20. If the bending portions 33 were formed along substantially the entire length of the extension direction of one side of the panel, as in the past, the length of the portion to be bent would be long and would require a lot of processing work, but if the bending portions 33 are formed in three locations rather than along substantially the entire length of one side, as in this embodiment, it is possible to reduce the processing work and improve manufacturing efficiency.

[0037] Since the bent portions 33 are formed on the long sides of the rectangular face material 20, the bent portions 33 can position the core material 23 in the width direction until the adhesive hardens.

[0038] The length A1 of the bent portion 33 in the width direction is short, ranging from 5 mm to 100 mm, so that the bending process is not time-consuming.

[0039] A recess 43b is formed in the base end 33a of the bending portion 33 on the face material 20 side, recessed inward in the width direction of the bending portion 33. As a result, even if the connecting portion 43 bulges outward in the width direction due to the influence of the plate thickness, hardness, etc. of the connecting portion 43 when bending, the base end 43a of the connecting portion 43 has the recess 43b formed inward in the width direction of the connecting portion 43, so that the connecting portion 43 can be bent at a substantially right angle.

[0040] An end face 33d of the tip end 33c of the bent portion 33 has an uneven fracture surface portion 35 formed on the surface 43d side of the panel 20. By positioning the fracture surface portion 35 so that it is positioned on the inside side of the sub-door 2 when the bent portion 33 is bent, exposure of the fracture surface portion 35 can be suppressed.

[0041] The pair of flat plate portions 42, 42 are not cut until the three sides of the flat plate portion 42 are bent to form the end surface portion 32. The process up to the bending of the end surface portion 32 can be carried out by placing the door on a processing device that can handle the width of two sub-doors 2.

[0042] Since the V-shaped groove 44 is formed in the connecting portion 43, when cutting the connecting portion 43, the cutting can be done along the groove 44, which improves the workability of the cutting.

[0043] While preferred embodiments of the present disclosure have been described above with reference to the accompanying drawings, it goes without saying that the present disclosure is not limited to these examples. The shapes and combinations of the components shown in the above examples are merely examples, and various modifications can be made based on design requirements, etc., without departing from the spirit of the present disclosure.

[0044] The bent portion 33 may be formed on at least one side of the surface portion 31, and may be formed on an edge portion other than the edge portion 31d on the door leading side.

[0045] In the above embodiment, the shoji screen is described as a sub-door 2, but it is not limited to this. It may be a main door 3, a single hinged shoji screen, or a shoji screen that fits into a sliding door. [Explanation of symbols]

[0046] 1 frame body, 2 child door (shoji), 3 parent door (shoji), 20, 20A, 20B face material, 23 core material, 31 face portion, 33 bent portion, 33a base end portion, 33b recessed portion, 33c tip portion, 33d end surface, 34 shear surface portion, 35 fracture surface portion, 42 flat plate portion, 43 connection portion, 44 groove portion, 100... fittings

Claims

1. A pair of face members formed of steel plates and arranged opposite each other; a core material disposed between the pair of face materials, The face material is A surface portion formed in a rectangular shape; a bent portion formed on at least one side of the face portion and bent toward the opposing face material, The bent portion is formed at a plurality of locations along the extending direction of the one side, A shoji screen in which the tip ends of the folded portions of the pair of panel members are spaced apart from each other.

2. The shoji screen according to claim 1, wherein the bent portion is formed on a long side of the panel.

3. 3. The shoji screen according to claim 1, wherein the width of the folded portion is 5 mm to 100 mm.

4. 3. A shoji screen according to claim 1, wherein a recess is formed in the base end of the bent portion on the side of the panel, the recess being recessed toward the center in the width direction of the bent portion.

5. The end surface of the tip of the bent portion is A shear surface portion disposed on one surface side of the face material and formed in a streak shape along a direction perpendicular to the plate surface of the face material; 3. The shoji screen according to claim 1, further comprising a fractured surface portion having an uneven surface formed thereon, the fractured surface portion being disposed on the other surface side of the panel.

6. A steel plate is processed so that one sides of a pair of rectangular flat plate portions are adjacent to each other, the one sides of the pair of flat plate portions are connected to each other by a connection portion, and the connection portion is formed at a plurality of locations along the extension direction of the one side, The flat plate portion is folded at three sides other than the one side, The connecting portion is cut so that a part of the connecting portion is connected to each of the pair of flat plate portions, and the pair of flat plate portions are separated, The connecting portion connected to one of the flat plate portions is bent, and the bent connecting portion is arranged along the core material, A method for manufacturing a shoji screen, in which the connection portion connected to the other flat plate portion is bent and positioned so that it faces one of the flat plate portions with the core material in between, and the connection portion of the other flat plate portion is positioned along the core material.

7. A V-shaped groove recessed toward the other surface is formed on one surface of the connection portion, The method for manufacturing a shoji screen according to claim 6, wherein the pair of flat plate portions are separated by cutting along the groove portions.

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