Curved architectural panel and method of manufacturing same

Abstract: A curved panel in which various shapes of a curved surface can easily be obtained only by curving the body proper of the panel and by fixing reinforcing plates thereto. An object of this curved panel is to provide such various effects as: size reduction in the working equipment; adaptability to a variety of specifications; cut in manufacturing cost; and more refined shape of the curved surface. For attaining the object, the curved panel is provided with deformed and bent pieces to permit bending of a surface plate and to be formed on two opposing sides of the surface plate capable of elastic deformation, and reinforcing bent pieces are formed on the other opposing two sides for keeping these two sides straight. On the other hand, reinforcing plates are formed to be smaller in curvature than said specified surface. Reinforcing plates are fixed to the forcedly curved pieces of the panel proper so that elastic shape-keeping force by which the panel proper tends to be restored to a flat surface may be balanced with elastic shape-keeping force of the reinforcing plate in order to provide a specified curve surface.

Description: The present invention relates to a curved architectural panel according to claim 1 and a method of manufacturing a curved architectural panel according to claim 10. From each of the documents JP-62-89413 and JP-55-27397 methods of attaching a curved architectural panel to a piece of furniture are known. Especially, in figure 4 of the document JP-55-27397 a panel is shown which comprises recesses for being appropriately fitted to the piece of furniture, for example by gluing. From figure 4c of the other document JP-62-89413 it is known to provide a decorative panel with projections. Such a panel can be fitted to a piece of furniture by engaging the projections of the decorative panel with corresponding recesses formed in the piece of furniture. Furthermore, from the document EP-A-0 321 006 a curved panel is known. This curved panel is manufactured such that pre-curved reinforcing members and a plane panel body are assembled together. The pre-curved reinforcing members are substantially stiffer and inflexible compared with the panel body. Because of the stiffness and inflexibility of the reinforcing members, the diameter of the reinforcing members before assembling is identical with the diameter of the reinforcing members after assembling. The recent tendency in designing furniture and architecture is that curved surfaces are positively employed in various parts from the viewpoint of design and function. Works produced from such a viewpoint are for example desks and tables having curved front panels, doors and partition walls the whole face plates of which are curved, arched ceilings having curved interior surfaces, and pillars circumferentially covered with a decorative hollow cylindrical member. The front panels, face plates, interior surfaces and decorative members of the above-mentioned types are usually made of steel plate by pressing. For pressing such material those dies which comform to the desired shapes of the products are required. If the above-mentioned relatively large-sized panel is to be formed by this method, the die must be as large as the panel to be formed and becomes expensive. As many dies as there are various kinds of products are required, with resulting increase in the manufacturing cost. Large-sized dies would necessarily require a large-sized machine. Since pressing utilizes plastic deformation, a strain is left in the pressed part after the exterior force has been removed. Therefore, the larger the curved surface is, the higher degree of precision is required for pressing. Otherwise, an unnecessarily large strain would be left in the pressed workpiece, so that it would become difficult to produce a good curved surface in the finished product. The object of the invention is to provide a curved architectural panel which can easily be manufactured. The above-mentioned object is achieved by means of a curved architectural panel according to claim 1. Such a curved architectural panel can be manufactured by means of the method according to claim 10. Furthermore, this invention shall provide a curved panel which has various advantages such that it is possible to reduce the size of the apparatus, easily produce products of various specifications, reduce the manufacturing cost and improve the quality of the finished curved surface. Preferred embodiments of the curved architectural panel are disclosed in the dependent claims 2 to 9. The curved architectural panel of the invention comprises a panel body and a pair of reinforcing members and is so arranged that the resilient force of the panel body to be restored to a flat condition balances the resilient force of the reinforcing members so as to keep the panel body at a predetermined curvature. The panel body is a flat member made of resiliently deformable material and comprises a face portion at each of the two opposite sides of which a deformable bent portion is provided which allows the face portion to be curved and at each of the other two opposite sides of which a reinforcing bent portion is provided which keeps the other two opposite sides of the face portion linear; and that the reinforcing members have a curvature greater than the above-mentioned predetermined curvature, and are fixed to the deformable bent portions of the panel body having been forcedly curved. The curvature of the panel body need not necessarily be uniform over the whole face portion of the panel body. In particular, if the face portion is divided into minute sections along the length of the deformable bent portions, each of the sections may have a different curvature from those of the other sections provided that the reinforcing members have a greater curvature in each corresponding section. Some of the sections of the panel body may be plane. The description that the curvature is relatively great means that the radius of curvature is smaller except in linear sections. In the panel body of the above construction, with the two opposite sides thereof provided with the reinforcing bent portions being kept linear, the other two opposite sides thereof provided with the deformable bent portions are curved by application of an artificial force thereto along the curve of the reinforcing members, and the reinforcing members are fixed to the curved bent portions, and then the artificial force is removed, whereupon the resilient force of the panel body to be restored to a plane counteracts the resilient force of the reinforcing members to be restored to their original curvature in opposite directions to each other, so that they balance to keep the panel body at a desired curvature. The processing steps required for the curved panel are to form the deformable bent portions and the reinforcing bent portions at each pair of sides of the panel and to form the reinforcing members. To make the panel it suffices to work an elongated member and it is not necessary to work the whole of a plate. Therefore, when a large panel is to be made, a smaller machine suffices as compared with pressing the whole of a plate, with resulting reduction of the cost involved. If products of various specifications are to be made, the curvature of the reinforcing members has only to be changed without increasing the cost involved. Since in accordance with this method the panel is curved within the range of its elasticity, the force to restore the panel to its plane condition acts to remove strain uniformly all over the face portion of the panel, so that the panel has a curved surface of very high quality. The invention may also be accomplished by the following embodiments. The deformable bent portion may be a flange provided with cuts longitudinally spaced apart, or an L-shaped portion provided with cuts longitudinally spaced apart, or a portion shaped like the letter of ⊐ and provided with cuts longitudinally spaced apart. The reinforcing member may be a reinforcing plate made by bending a steel to an L-shape in cross section, a reinforcing channel member made by bending a steel plate to the letter of ⊐ in cross section, a reinforcing pipe made by bending a steel plate, or a member made of a shape memory alloy which is restored to a greater curvature than a desired curved surface when heated above the normal temperature. In the following the invention is further illustrated by embodiments with reference to the enclosed drawings. Figs. 1 to 8 show one embodiment of the invention. Fig. 1 is a perspective view of the curved panel; Fig. 2 is a perspective view of part of the panel body before it is resiliently curved; Fig. 3 is a plan view of the part shown in Fig. 3 in unfolded condition; Fig. 4 is a perspective, exploded view of the panel; Fig. 5 is a transverse view of a modified form of the deformable bent marginal portion of the panel; Fig. 6 is a perspective view of part of the panel after assemblage; Fig. 7 is a view showing the operation of the invention; and Fig. 8 is a view showing an example of use. Figs. 9 through 16 are transverse views similar to Fig. 5 but showing different embodiments of the invention. As shown in Fig. 1, the curved panel A comprises a curved panel body 1 and a pair of reinforcing plates 2 fixed to the opposite sides of the panel body 1 so that the resilient force of the panel body 1 to be restored to its flat condition is balanced by the resilient force of the reinforcing plates 2 to be restored to their original shape in the opposite direction thereby to keep the panel body 1 in a desired curved condition. In particular, the panel body 1 is a thin steel plate, which is provided at its two opposite sides la, la with a deformable bent portion 12 having a plurality of sawtooth cuts 11, and at the other two opposite sides 1b, 1b with a reinforcing bent portion 13 without such sawtooth cuts formed therein. To form the bent portions 12 and 13, a steel plate is stamped so that along the four sides of a face plate portion lc bendable marginal portions 12a and 13a are left, which are then deformed like the letter of L in cross section by roll forming. The bent marginal portions 12 and 13 are connected at the four corners by welding. In the stamping process the sawtooth cuts 11 are formed in the bendable marginal portions 12a. The cuts 11 are V-shaped and have a bottom not pointed but rounded. Due to the arrangement, when an exterior force acts on the face portion lc of the panel body 1, the face portion 1c is comparatively easily curved along the deformable bent portions 12, but hardly along the reinforcing bent portions 13. As shown in Figs. 1 and 4, the reinforcing members 2 are made of a thick steel plate cut by laser into an arcuate member having a curvature slightly greater than that of the curved surface of the panel to be manufactured. The reinforcing members have a cross-sectional shape substantially corresponding to that of the space defined inside the deformable bent portions 12 and a length substantially equal to that of the bent portions 12. With the opposite sides of the panel body 1 provided with the reinforcing bent portidns 13 being held straight, an artificial force is applied to the two opposite sides of the panel body 1 provided with the deformable bent portions 12 so as to curve it into conformity with the curvature of the reinforcing members 2 as shown in Fig. 4, and the reinforcing members 2 are placed inside the upper and lower bent portions 12 of the curved panel body 1 and secured therein by spot welding as shown in Figs. 5 and 6. Then the artificial force is removed to complete the assembly. Under the conditon, as shown in Fig. 7, the resilient force F1 of the panel body 1 to be restored to the flat condition shown in phantom line counteracts the resilient force F2 of the reinforcing member 2 to be restored to the original curvature shown in phantom line, so that the panel body 1 and the reinforcing member 2 take the intended curvature at the position shown in real line where the two forces balance. Since the curved panel A is of the above-mentioned construction, the processing steps required of making the illustrated embodiment is the roll forming step to form the deformable bent portions 12 and the reinforcing bent portions 13 at the two opposite sides 1a, 1a and 1b, 1b, respectively, and the cutting step by laser to form the reinforcing plates 2. Thus it is possible to complete production of the panel A by merely processing an elongated member, so that when a large-sized panel is to be made, a smaller machine tool suffices than if the whole surface of a plate is machined by a press, with resulting reduction of the manufacturing cost. Moreover, since laser cutting is generally conducted by numerical control, it is possible to change the curvature of the reinforcing plates by merely changing the set numerical values, thereby to easily produce curved panels of different specifications. In addition, since according to the method the face portion 1c of the panel body 1 is curved within the range of its elasticity, the force to restore the curved face portion lc to its flat condition acts to remove strain in each and every part thereof, thereby to produce a good curved surface at the portion where it balances the reinforcing plates 2. If the curved panel A is used as the front panel of a conference table B as shown in Fig. 8, it is possible to make tables of different radii, without increasing the panel size and the number of kinds of panels and consequently the manufacturing cost. The improved quality of the curved surface of the front panel gives a good appearance to the whole table. The invention is not limited to the above described embodiment. In the above embodiment, the bent portion 12 is shaped like the letter of L. A flange-like bent portion 112 as shown in Figs. 9, 10, 11, 12, or a bent portion 212 shaped like the letter of ⊐ as shown in Fig. 16 may also be used. In the above embodiments, the reinforcing members 2 are made of a thick steel plate cut to the required shape. It can also be a reinforcing angle 102 made of a steel plate bent to an L-shape in transverse section as shwon in Figs. 10, 13 and 16, or a reinforcing channel-like member 202 made of a steel plate bent to a transverse shape like the letter of ⊐ as shown in Figs. 11 and 14, or a reinforcing pipe 302 made by bending a steel plate to the shape as shown in Figs. 12 and 15. These members may be fixed to the panel body by means of spot welding. Aternatively, it is advantageous to provide the deformable bent portions 12 with a claw 112 as shown in Fig. 13 or the reinforcing angle 102 with a claw 112a as shown in Fig. 16 for preventing the reinforcing member or the angle from falling off the panel body. The reinforcing member may also be made of a shape memory alloy which is restored to a greater curvature than a desired curvature when heated to a higher temperature than the normal temperature. The steel plate may be a steel plate covered by venyl chroride film, a coated steel plate, a stainless steel plate, or a resiliently deformable synthetic resin plate. Besides the above-mentioned conference table, the curved panel may also be used in a desk whose front panel has a curved surface, a door or a partition wall whose whole surface is curved, an arched ceiling whose inner surface is curved, or a pillar whose outer circumference is covered with a hollow cylindrical decorative member. Several embodiments having been described, the invention is not restricted to them but there may be various modifications without departing from the invention as defined in the appended claims. POSSIBLE APPLICATIONS IN INDUSTRY As mentioned above, the curved panel of the invention is useful in application to a desk or a table whose front panel is curved, a door or a partition wall whose whole surface is curved, an arched ceiling whose inner surface is curved or a pillar whose outer circumference is covered with a hollow cylindrical decorative member.

Claims: An architectural curved panel comprising a panel body (1) and a reinforcing means (2;102;202;302), wherein the panel body (1) is a flat member made of resiliently deformable material and comprising a face portion (1c) at each of the two opposite sides (1a) of which a deformable bent portion (12) is provided which allows the face portion to be curved and at each of the other two opposite sides (1b) of which a reinforcing bent portion (13) is provided which keeps the other two opposite sides of the face portion (1c) linear; wherein said reinforcing means comprises a pair of reinforcing members (2;102;202;302) fixed to the deformable bent portion (12) of the panel body (1) having been forcedly curved, so that the resilient force of the panel body to be restored to a flat condition balances the resilient force of the reinforcing members so as to keep the panel body at a predetermined curvature, which is smaller than the original curvature of said reinforcing member. An architectural curved panel according to claim 1, wherein each of the deformable bent portions (12) is shaped like a flange and provided with a plurality of cuts (11) longitudinally spaced apart. An architectural curved panel according to claim 1, wherein each of the deformable bent portions (12) is L-shaped and provided with a plurality of cuts (11) longitudinally spaced apart. An architectural curved panel according to claim 1, wherein each of the deformable bent portions (12) is U-shaped and provided with a plurality of cuts (11) longitudinally spaced apart. An architectural curved panel according to claim 2 or 3, wherein each of the reinforcing members (2) is a reinforcing plate made by cutting a thick steel plate. An architectural curved panel according to claim 2, 3 or 4, wherein each of the reinforcing members (102) is a reinforcing angle made by bending a steel plate to an L-shape in transverse section. An architectural curved panel according to claim 2 or 3, wherein each of the reinforcing members (202) is a reinforcing channel member made by bending a steel plate to a U-shape in transverse section. An architectural curved panel according to claim 2 or 3, wherein each of the reinforcing members (302) is a reinforcing pipe made by bending a steel plate. An architectural curved panel according to claim 1, wherein each of the reinforcing members (2;102;202;302) is made of a shape memory alloy so that they may be restored to a curvature greater than a predetermined curvature. A method of manufacturing a curved architectural panel comprising the steps of providing a panel body (1) and a pair of reinforcing members (2;102;202;302), wherein the panel body (1) is a flat member made of resiliently deformable material and comprising a face portion (1c), providing a deformable bent portion (12) at each of the two opposite sides (1a) of the face portion (1c), said deformable bent portion (12) allowing the face portion to be curved and providing a reinforcing bent portion (13)at each of the other two opposite sides (1b) of the face portions (1c), said reinforcing bent portion (13) keeping the other two opposite sides of the face portion (1c) linear, and fixing said reinforcing members to the deformable bent portion (12) of the panel body (1) having been forcedly curved, so that the resilient force of the panel body to be restored to a flat condition balances the resilient force of the reinforcing members so as to keep the panel body at a predetermined curvature, which is smaller than the original curvature of said reinforcing member.

Inventors: KANEDA SHINICHI, TANAKA MAMORU, KANEDA, SHINICHI, TANAKA, MAMORU
Applicants: KOKUYO KK, KOKUYO CO., LTD.
Application year: 1991
Main classification: F16S1
IPC codes: A47B96, E04C2, A47B83, E04F13