A door includes a single panel folded to form a latch face and first and second main faces of the door. The door preferably further includes edge tabs folded to form upper, lower and hinge faces of the door. The panel is preferably a composite panel including an inner metal sheet, an outer metal she
A door includes a single panel folded to form a latch face and first and second main faces of the door. The door preferably further includes edge tabs folded to form upper, lower and hinge faces of the door. The panel is preferably a composite panel including an inner metal sheet, an outer metal sheet, and a plastics core material between the metal sheets.
대표청구항▼
1. A door, comprising: a single panel having an upper edge, a lower edge opposite said upper edge, a first side edge, a second side edge opposite said first side edge, said single panel being comprised of an inner sheet, an outer sheet, and a core between said inner sheet and said outer sheet,wherei
1. A door, comprising: a single panel having an upper edge, a lower edge opposite said upper edge, a first side edge, a second side edge opposite said first side edge, said single panel being comprised of an inner sheet, an outer sheet, and a core between said inner sheet and said outer sheet,wherein said single panel comprises: a first main section defined by said upper edge, said first side edge, said lower edge and a first V-shaped groove, said first V-shaped groove extending from said upper edge to said lower edge in a mid portion of the panel;a second main section defined by said upper edge, said second side edge, said lower edge and a second V-shaped groove, said second V-shaped groove extending from said upper edge to said lower edge in said mid portion of the panel; anda latch section between said first main section and said second main section, said latch section being defined by said upper edge, said lower edge, said first V-shaped groove, and said second V-shaped groove,wherein said first V-shaped groove and said second V-shaped groove are parallel to each other,wherein said first main section is folded along said first V-shaped groove relative to said latch section, said outer sheet of said first main section forming a first main face,wherein said second main section is folded along said second V-shaped groove relative to said latch section, said outer sheet of said second main section forming a second main face,wherein said outer sheet of said latch section forms a latch face, said first main face being parallel to said second main face,wherein said first side edge and said second side edge form a hinge face,wherein said upper edge comprises an upper additional groove in said inner sheet, a first upper cutout between said first main section and said latch section, and a first upper side cutout between said first main section and said first side edge so as to form a first main section upper edge tab, a second upper cutout between said second main section and said latch section, and a second upper side cutout between said second main section and said second side edge so as to form a second main section upper edge tab and a latch section upper edge tab,wherein said lower edge comprises a lower additional groove in said inner sheet, a first lower cutout between said first main section and said latch section, and a first lower side cutout between said first main section and said first side edge so as to form a first main section lower edge tab, a second lower cutout between said second main section and said latch section, and a second lower side cutout between said second main section and said second side edge so as to form a second main section lower edge tab and a latch section lower edge tab,wherein said first side edge comprises a first side additional groove, said first side additional groove, said first upper side cutout, and first lower side cutout forming a first side edge tab,wherein said second side edge comprises a second side additional groove, said second side additional groove, said second upper side cutout, and second lower side cutout forming a second side edge tab,wherein said first main section upper edge tab, said latch section upper edge tab, and said second main section upper edge tab are folded toward each other so as to form an upper face,wherein said first main section lower edge tab, said latch section lower edge tab, and said second main section lower edge tab are folded toward each other so as to form a lower face,wherein said first side edge tab and said second side edge tab are folded toward each other so as to form said hinge face,wherein said latch section upper edge tab is triangular,wherein said first main section upper edge tab and said second main section upper edge tab have shapes complementary to said latch section upper edge tab, said first main section upper edge tab being contiguous with said second main section upper edge tab and said latch section upper edge tab so as to form said upper face,wherein said latch section lower edge tab is triangular,wherein said first main section lower edge tab and said second main section lower edge tab have shapes complementary to said latch section lower edge tab, said first main section lower edge tab being contiguous with said second main section lower edge tab and said latch section lower edge tab so as to form said lower face,wherein said first side edge tab has a first upper side edge tab portion and a first lower side edge tab portion;wherein said second side edge tab has a second upper side edge tab portion and a second lower side edge tab portion;wherein said first side edge tab is contiguous with said second side edge tab so as to form said hinge face, said first upper side edge tab portion being contiguous with said first main section upper edge tab so as to form said upper face with a corresponding rounded folded edge on said hinge face, said second upper side edge tab portion being contiguous with said second main section upper edge tab so as to form said upper face with a corresponding rounded folded edge on said hinge face, said first lower side edge tab portion being contiguous with said first main section lower edge tab so as to form said lower face with a corresponding rounded folded edge on said hinge face, said second lower side edge tab portion being contiguous with said second main section lower edge tab so as to form said lower face with a corresponding rounded folded edge on said hinge face. 2. The door, according to claim 1, wherein the panel is comprised of a composite material, andwherein said first V-shaped groove and said second V-shaped groove extending to said core from said inner sheet toward said outer sheet. 3. The door, according to claim 2, wherein said core is comprised of a thermosetting plastic. 4. The door, according to claim 1, further comprising: infill material disposed between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section. 5. The door, according to claim 4, wherein said infill material is positioned between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section. 6. The door, according to claim 5, wherein said infill material is selected from a group consisting of polyurethane and polyethylene. 7. The door, according to claim 1, further comprising: fireproof material disposed between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section. 8. The door, according to claim 1, further comprising: a frame disposed between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section. 9. The door, according to claim 1, further comprising: a hinge having a door mount section attached to said first side edge tab and said second side edge tab of said hinge face. 10. The door, according to claim 1, wherein the panel is comprised of a flexible wrap material. 11. A method of forming a door, the method comprising: assembling a single panel having an upper edge, a lower edge opposite said upper edge, a first side edge, a second side edge opposite said first side edge, said single panel being comprised of an inner sheet, an outer sheet, and a core between said inner sheet and said outer sheet;forming a first V-shaped groove extending from said upper edge to said lower edge in a mid portion of the panel, wherein said upper edge, said first side edge, said lower edge and said first V-shaped groove define a first main section;forming a second V-shaped groove extending from said upper edge to said lower edge in said mid portion of the panel, wherein said upper edge, said second side edge, said lower edge and said second V-shaped groove define a second main section;forming a latch section between said first main section and said second main section, said latch section being defined by said upper edge, said lower edge, said first V-shaped groove, and said second V-shaped groove,wherein said first V-shaped groove and said second V-shaped groove are parallel to each other, folding said first main section along said first V-shaped groove relative to said latch section, said outer sheet of said first main section forming a first main face;folding said second main section along said second V-shaped groove relative to said latch section, said outer sheet of said second main section forming a second main face,wherein said outer sheet of said latch section forms a latch face, said first main face being parallel to said second main face, andwherein said first side edge and said second side edge form a hinge face; forming a first main section upper edge tab in said upper edge with an upper additional groove in said inner sheet, a first upper cutout between said first main section and said latch section, and a first upper side cutout between said first main section and said first side edge;forming a second main section upper edge tab and a latch section upper edge tab with a second upper cutout between said second main section and said latch section, and a second upper side cutout between said second main section and said second side edge;forming a first main section lower tab in said lower edge with a lower additional groove in said inner sheet, a first lower cutout between said first main section and said latch section, and a first lower side cutout between said first main section and said first side edge;forming a second main section lower edge tab and a latch section lower edge tab with a second lower cutout between said second main section and said latch section, and a second lower side cutout between said second main section and said second side edge;forming a first side edge tab with a first side additional groove, said first side additional groove, said first upper side cutout, and first lower side cutout;forming a second side edge tab with a second side additional groove, said second side additional groove, said second upper side cutout, and second lower side cutout;folding said first main section upper edge tab, said latch section upper edge tab, and said second main section upper edge tab toward each other so as to form an upper face;folding said first main section lower edge tab, said latch section lower edge tab, and said second main section lower edge tab toward each other so as to form a lower face;folding said first side edge tab and said second side edge tab toward each other so as to form said hinge face, wherein said latch section upper edge tab is triangular, wherein said first main section upper edge tab and said second main section upper edge tab have shapes complementary to said latch section upper edge tab, said first main section upper edge tab being contiguous with said second main section upper edge tab and said latch section upper edge tab so as to form said upper face, wherein said latch section lower edge tab is triangular, wherein said first main section lower edge tab and said second main section lower edge tab have shapes complementary to said latch section lower edge tab, said first main section lower edge tab being contiguous with said second main section lower edge tab and said latch section lower edge tab so as to form said lower face,wherein said first side edge tab has a first upper side edge tab portion and a first lower side edge tab portion;wherein said second side edge tab has a second upper side edge tab portion and a second lower side edge tab portion; andfolding said first upper side edge tab portion and said second upper side edge tab portion so as to form said upper face;folding said first lower side edge tab portion and said second lower side edge tab portion so as to form said lower face;wherein said first side edge tab is contiguous with said second side edge tab so as to form said hinge face, said first upper side edge tab portion being contiguous with said first main section upper edge tab so as to form said upper face with a corresponding rounded folded edge on said hinge face, said second upper side edge tab portion being contiguous with said second main section upper edge tab so as to form said upper face with a corresponding rounded folded edge on said hinge face, said first lower side edge tab portion being contiguous with said first main section lower edge tab so as to form said lower face with a corresponding rounded folded edge on said hinge face, said second lower side edge tab portion being contiguous with said second main section lower edge tab so as to form said lower face with a corresponding rounded folded edge on said hinge face. 12. The method of forming a door, according to claim 11, wherein the panel is comprised of a composite material, said core being comprised of a plastic material,wherein the step of forming said first V-shaped groove comprises cutting into said inner sheet and partially into said core, andwherein the step of forming said second V-shaped groove comprises cutting into said inner sheet and partially into said core. 13. The method of forming a door, according to claim 11, further comprising the steps of: inserting a frame between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section. 14. The method of forming a door, according to claim 11, further comprising the steps of: inserting an infill material between said inner sheet corresponding to said first main section and said inner sheet corresponding to said second main section as a liquid; andsolidifying said infill material as a foam. 15. The method of forming a door, according to claim 11, further comprising the steps of: mounting a hinge 90 having a door mount section, said door mount section being attached to said first side edge tab and said second side edge tab of said hinge face.
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