U.S. patent application number 10/535170 was filed with the patent office on 2006-02-23 for fabrication af hollow door using modular panel rib components made from scrap wood.
Invention is credited to Tong Seng Yong, Toong Chuan Yong.
Application Number | 20060037281 10/535170 |
Document ID | / |
Family ID | 32590097 |
Filed Date | 2006-02-23 |
United States Patent
Application |
20060037281 |
Kind Code |
A1 |
Yong; Toong Chuan ; et
al. |
February 23, 2006 |
Fabrication af hollow door using modular panel rib components made
from scrap wood
Abstract
A wooden door with panel ribs (2.10, 2.12, 2.14) in the hollow
core of the door wherein the ribs are made from scrap wood pieces.
Since the scrap wood pieces are usually too short for this purpose,
a method is also described that teaches means to connect the ribs
made from the scrap wood pieces into useful lengths by the use of
notches, connector blocks and conventional fasteners.
Inventors: |
Yong; Toong Chuan;
(Singapore, SG) ; Yong; Tong Seng; (Singapore,
SG) |
Correspondence
Address: |
LAWRENCE Y.D. HO & ASSOCIATES PTE LTD
30 BIDEFORD ROAD, #07-01, THONGSIA BUILDING
SINGAPORE
229922
SG
|
Family ID: |
32590097 |
Appl. No.: |
10/535170 |
Filed: |
April 11, 2003 |
PCT Filed: |
April 11, 2003 |
PCT NO: |
PCT/SG03/00078 |
371 Date: |
May 16, 2005 |
Current U.S.
Class: |
52/784.14 |
Current CPC
Class: |
E06B 3/7017 20130101;
E04C 2/36 20130101 |
Class at
Publication: |
052/784.14 |
International
Class: |
E04C 2/54 20060101
E04C002/54 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 16, 2002 |
SG |
200207576-0 |
Claims
1. A method of fabricating hollow doors of wood material with at
least one panel rib joined from modular components rendered from
scrap wood material, said modular components comprising engagement
members, complementary engagement members and connecting means.
2. A method in accordance to claim 1, said joining of said panel
rib's said engagement members and said complementary engagement
members do not require adhesive due to complementary structures of
said engagement members and said complementary engagement
members.
3. A method in accordance to claim 1, said method further comprises
joining modular components of inadequate individual dimensions to
form a panel rib, such that panel ribs of adequate dimensions may
be fabricated.
4. The method according to claim 1, wherein said engagement members
and said complementary engagement members comprise notched
components that can be joined one to another.
5. A method in accordance to claim 1, said method further comprises
assembling a latticework comprising panel ribs formed from modular
components, and other components formed from non-scrap wood
material.
6. A method in accordance to claim 5, said method of assembling
said latticework may be performed within a frame for a hollow
door.
7. A method in accordance to claim 5, said method of assembling
said latticework may be performed before placing said latticework
into a frame for a hollow door.
8. A method in accordance to claim 5, said method of assembling
said latticework permit latticeworks of different configurations to
be readily formed.
9. A hollow door of wood material with at least one panel rib
joined from modular components rendered from scrap wood material,
said modular components comprising engagement members,
complementary engagement members and connecting means.
10. A hollow door in accordance to claim 9, said joining of said
panel rib's said engagement members and said complementary
engagement members do not require adhesive due to complementary
structures of said engagement members and said complementary
engagement members.
11. A hollow door in accordance to claim 9, said panel rib further
comprises modular components of inadequate individual dimensions to
form said panel rib, wherein joining of said modular components
allow panel ribs of adequate dimensions to be fabricated.
12. A hollow door in accordance to claim 9, said engagement members
and said complementary engagement members comprise notched
components that can be joined one to another.
13. A hollow door in accordance to claim 9, said connecting means
comprise fasteners.
14. A hollow door in accordance to claim 9, said hollow door
further comprises a latticework of panel ribs formed from modular
components, and other components formed from non-scrap wood
material.
15. A hollow door in accordance to claim 14, said latticework may
be assembled within a frame for a hollow door.
16. A hollow door in accordance to claim 14, said latticework may
be pre-assembled before placing said latticework into a frame for a
hollow door.
Description
FIELD OF THE INVENTION
[0001] The present invention relates wooden hollow doors fabricated
with parts of scrap wood and wood composites.
[0002] In particular, the present invention relates to a hollow
door using modular panel rib components and the method of
fabricating the hollow door.
BACKGROUND OF THE INVENTION
[0003] At present, hollow doors are constructed primarily of wood
or wood composites. Such doors have a frame defining the shape and
size of the door with panels or "skins" that form the two flat
vertical sides of the door.
[0004] The hollow core of the door has ribs or spacers between the
skins to give the door structural strength while keeping the
overall weight of the door low.
[0005] The spacers are usually made of a flexible honeycomb of
paper or cardboard, glued to the skins of the door.
[0006] While materials used may differ, similar methods of
fabrication have also applied to partition panels, signboards,
cabinets, writing (white or black) boards, table-tops, floors and
ceiling panels, all of which utilize the same construction: that of
panels separated by spacers.
[0007] One problem with using virgin wood strips as is the cost and
weight in addition, wood is getting scarce. One way to reduce
reliance on virgin wood material is to substitute it with paper or
cardboard as a spacer material. However, paper and cardboard is
susceptible to moisture and dampness.
[0008] Another problem is that significant portion of the cost of
the items is due to the manufacturing cost of the paper or
cardboard honeycombs as specialized equipment are needed.
[0009] These problems in the current art are especially ironic
since carpentry factories and workshops fabricating hollow doors
and other furnishings generate a lot of off-cuts or scrap wood.
Left unused, this scrap wood is usually disposed of as waste.
SUMMARY OF THE INVENTION
[0010] The present invention seeks to provide a method to render
scrap wood or wood composites into modular components for the
manufacture of wood hollow doors.
[0011] In particular, the present invention teaches methods for the
rendering scrap wood or wood composites into modular components of
panel ribs, elements of the present invention, for the manufacture
of hollow wooden doors.
[0012] In another aspect, the present invention is a hollow door
fabricated according to the methods of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A preferred embodiment of the present invention will now be
more fully described, by way of example, with reference to the
drawings of which:
[0014] FIG. 1 illustrates two hollow doors with the panel or "skin"
from one side is partially removed to expose the hollow core of the
door occupied by a honeycomb of paper one (FIG. 1A) and a modular
latticework made from scrap wood in the other (FIG. 1B);
[0015] FIG. 2 shows the method of making panel ribs from short
pieces of scrap wood using notches and connector blocks;
[0016] FIG. 3 shows the method of fastening panel ribs to a
connector block in a radial pattern using conventional woodworking
fasteners;
[0017] FIG. 4 shows how panel ribs may be joined with a notched
connector; and
[0018] FIG. 5 shows two possible lattice arrangements in hollow
doors under the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] In accordance with the present invention, methods of
rendering scrap construction or manufacturing materials,
particularly off-cuts from wood and wood composites into modular
components, and a preferred embodiment of the invention,
fabrication of a hollow door, are described.
[0020] In the following description, details are provided to
describe the preferred embodiment. It shall be apparent to one
skilled in the art, however, that the invention may be practiced
without such details. Some of these details may not be described at
length so as not to obscure the invention.
[0021] Here, all reference to wood material also refers to wood
composites. Similarly, references to paper also refer to cardboard.
As in the industry, the panels of the hollow doors are also
referred to as "skins" in the present application.
[0022] The terms "connector" and "connector block" are also used
interchangeably in the present invention. Both are used to join
modular components to form panel ribs.
[0023] One aspect of the present invention is a method of rendering
scrap wood into modular components for the assembly of panel ribs.
This is done by making use of various ways to connect the modular
components into a latticework of panel ribs to replace the paper or
cardboard honeycomb between panels of the finished product.
[0024] While hollow doors may be made of materials other than wood,
the present invention is directed to the panel ribs of hollow doors
and similar products made of wood and wood composite. However,
hollow doors fabricated of materials other than wood or wood
composite but utilizing the method taught in the present invention
are within the scope and spirit of the present invention.
[0025] There are many advantages of the present invention. One
advantage is that scrap wood may be used as panel ribs. Scrap wood
or waste wood is also called "off-cuts". These are the remnants of
wood left over from furniture manufacturing. They come in odd sizes
and are usually of lengths too short to be useful for other
purposes and are usually disposed of as waste.
[0026] This invention teaches methods of rendering these short
pieces of scrap wood into useful components for panel ribs, the
invention also teaches methods to join these components into useful
configurations for use in hollow doors and similar furnishings.
[0027] By advantageously utilizing this hitherto useless material,
the need to dispose of this scrap wood by either burning or dumping
is greatly reduced, allowing the present invention to contribute in
reducing impact on the environment.
[0028] Another advantage of the present invention is that wood,
especially wood composite, is more moisture resistant than paper or
cardboard. When used as panel ribs, the final product is more
durable in damp or humid environments.
[0029] Hollow doors made with wood panel ribs are structurally
stronger than those made with paper or cardboard honeycomb.
[0030] While heart of the invention is the idea of joining modular
pieces of wood into panel ribs, the various methods of joining the
strips of wood are encompassed by the scope of the present
invention. Some examples of joining the wood strips through the use
of an engagement member (strip) and a complementary engagement
member (connector) are taught below.
[0031] Referring now to FIG. 1A and 1B, a door made with a paper
honeycomb 1.10 is compared with another made with panel ribs 1.12
as taught in the present invention.
[0032] In FIG. 2, it can be seen that short pieces or strips of
wood 2.10 are joined with complementary notches. These engagement
members and their complementary engagement members are elements of
the present invention.
[0033] One way is to join short strips of wood is through the use
of corresponding half notches 2.12 cut into the strips of wood.
Multiple strips of wood may be joined side by side by using notches
2.14 that are correspondingly as wide as the thickness
required.
[0034] While the joining of panel ribs with each other or with
connector blocks are shown as notches 2.12 and 2.14,
tongue-and-groove or mortise-and-tenon type joints (not shown) may
also be used.
[0035] Another way to join strips of off-cuts is by the use of
connector blocks (FIG. 3). Such connector blocks may be
rectangular, circular or polygonal in cross-section and be of
varying thickness. The use of connector blocks gives greater
latitude to the pattern of latticework possible and hence greater
usage of scrap wood.
[0036] For example, as may be seen in FIG. 3, a hexagonal 3.10 or
circular connector will allow panels ribs to be joined in a radial
pattern. In FIG. 3, the strips are joined to connector block 3.10
by means of conventional woodworking fasteners such as nails 3.12,
tacks, screws or angle plates.
[0037] Components described may join at angles to form a "T" joint,
an "L" or "V" joint or a rectangle.
[0038] Connector blocks also allow end-to-end joining of panel ribs
to form a longer strip of wood (FIG. 4). A connector that is
notched 4.16 may be readily joined to both strips with 4.17 or
without notches 4.18 at the ends. Means other than notches,
mortise-and-tenon joints may be used to join these modular
components under the present invention.
[0039] The complementary structures of these components cited above
allow these components to be connected without the need for
adhesives. This lowers costs and speeds up production.
[0040] Similarly, instead of using the methods or modular
components described above, the engagement members may also be
joined by the connecting means with conventional woodworking
fasteners such as nails, tacks or screws.
[0041] FIGS. 5A and 5B show two arrangements of latticework
fabricated under the scope of the present invention. The panel ribs
may be formed from a mixture of dedicated ribs 5.10 (eg the
vertical continuous strips) of virgin, non-scrap wood, and scrap
wood 5.12 (the diagonal ribs) or entirely of scrap wood 5.14 with
the methods of joining described above. FIG. 1B is an example
showing another possible arrangement of latticework under the
present invention.
[0042] Even with the use of some virgin material, scrap wood still
forms the bulk of the present invention, making it extremely
environmentally friendly.
[0043] To practise this invention, the method of joining strips
with notches is described as the preferred embodiment. Similar
fabrication procedures and a combination of the joining methods,
while not described in detail, may also be used.
[0044] Simple settings of a rip saw fence arrangement should first
be determined and set up. This will generate useful strips of
uniform width and thickness from the scrap wood.
[0045] Then a jig indicating the intervals at which to cut the
notches should be used to determine where the notches should be
cut. Although elaborate jigs may be used for this, a simple marked
straight edge may also suffice.
[0046] Strips with notches cut at regular intervals are then
rendered from scrap wood using the above arrangements.
[0047] Thus a ready supply of these modular components of uniformly
cut strips, may be generated for the fabrication of hollow
doors.
[0048] A hollow door is assembled as usual with the frame placed
over the skin or panel of one side and this arrangement secured. A
latticework of panel ribs may be assembled in place, in the hollow
of the door. Alternatively, the lattice may be assembled on a
schematic of the frame and then placed in the hollow defined by the
frame as a complete component.
[0049] The edges of the panel ribs in contact with the skin are
painted with a suitable adhesive and the panel ribs placed in
contact with the skin.
[0050] Again, wood glue or a suitable adhesive applied to the other
exposed narrow edges of the panel ribs. With the use of half
notches, the latticework of scrap wood need not be secured by any
adhesive as contact with the skins of the door will keep them in
place.
[0051] The skin of the other side is then place over the hollow
such that both skins contact the adhesive. The skins are then held
to the frame and panel ribs by presses until the glue has
cured.
[0052] When the glue or adhesive has dried or cured, the door is
trimmed and finished.
[0053] It will be apparent to anyone of ordinary skill in the art
that the procedure of fabricating a hollow door may be varied
significantly without affecting the finished product or departing
from the scope of the present invention.
[0054] Again, it will be appreciated by anyone of ordinary skill in
the art that handling the latticework of panel ribs is
significantly easier than a manipulating a honeycomb of paper or
cardboard.
[0055] The present invention is also non-obvious and entailed an
inventive step, as apparent from the lack of prior art teaching the
use of rendering and joining scrap wood strips into usable panel
ribs for hollow doors.
[0056] The different latticework of panel ribs may be varied to
suit the requirements of the door. If a stronger door is required,
a denser arrangement of panel ribs with more cross-linked members
may be used.
[0057] It will also be appreciated by anyone concerned with the
environment that maximizing the use of scrap wood in the present
invention is environmentally friendly and will reduce the use of
virgin material for the fabrication of hollow doors and products of
similar construction.
[0058] While a wood hollow door is described, it will also be
apparent to one of ordinary skill in the art that the invention may
also be practiced in the fabrication of other furnishings and
structures such as hollow partition panels, cabinets, writing
boards, desk and table tops, and signboards, all of which utilize
similar methods of construction and are hence within the scope of
the present invention.
[0059] Various improvements, particularly to methods of joining the
panel ribs together, may also be made without departing from the
scope of the present invention.
* * * * *