Integrally-formed hollow fireproof door leaf and process thereof

Abstract

The invention relates to the technical field of fireproof door leaves, and particularly discloses an integrally-formed hollow fireproof door leaf and a process thereof.The integrally-formed hollow fireproof door leaf comprises a fireproof door leaf core body, two layers of ash silicon plates are arranged on the two opposite sides of the fireproof door leaf core body, and a decorative surface layer is arranged on the surface of the side, away from the fireproof door leaf core body, of each ash silicon plate; a hinge side grey silicon plate strip is arranged between the two layers of grey silicon plates at one end of the fireproof door leaf core body, and a light hollow channel is formed in the fireproof door leaf core body. A series of structures are arranged, the forced requirement of the latest fireproof door for raw materials is met, halogenation is avoided, the A1-level fireproof performance can be achieved through a thin door body, the surface of the frame can be decorated, the weight of the door body can be customized, the material density of the door core part is adjustable and controllable, the structure is stable, performance is stable, and deformation caused by damp is avoided; the slurry is similar to the raw material components of the frame plate, the contact interface is firmly bonded, and the hollow structure can reduce the weight of the door body.

Description

Technical Field

[0001] This invention relates to the field of fireproof door technology, specifically to an integrally molded hollow fireproof door and its manufacturing process. Background Technology

[0002] Compared with the old standard, the new fire door standard has increased the quality and performance requirements of various materials used in the fire door leaf, and has higher requirements for the mechanical performance, smoke sealing performance and water jet impact resistance of the overall fire door structure.

[0003] The current disadvantages of wooden fire doors are as follows: 1. The door leaf is mostly made of inorganic boards such as calcium silicate board / magnesium oxide board combined with wood board to form the door surface, resulting in a high scrap rate; 2. High dimensional accuracy is required for the door core board. If the thickness deviation of the door core board is large, inorganic boards are prone to cracks and other defects that are difficult to detect during the pressing and drilling process, which introduces risks to the stability of the fire door; 3. Currently, most of the boards used are perlite boards, which have a high density and are prone to efflorescence when exposed to water and moisture, leading to a reduction in the fire resistance of the fire door; 4. The wooden surface is prone to deformation, affecting the overall surface performance of the door leaf. Excessive burning loss of the wooden surface during a fire can lead to loosening of the hardware and affect the smoke-sealing performance of the door leaf during a fire; 5. The inorganic boards such as calcium silicate board / magnesium oxide board used now have a high density and high hardness. The board body is prone to cracking during flame burning and is very easy to burn through during a fire, affecting the fire resistance, smoke-sealing performance and water jet impact resistance. The disadvantages of steel fire doors are: 1. The grouting process used on-site places high demands on equipment, maintenance techniques, and installation time; 2. The grout is prone to alkali return, which corrodes the steel plate and can even cause it to corrode through, making it difficult to repair; 3. The aesthetics are insufficient, making them unsuitable for locations with both high requirements for appearance and fire resistance; 4. The standard steel fire door thickness must not be less than 50mm, resulting in a heavy door leaf, which increases costs and makes the fire door less cost-effective. Therefore, fire doors with high fire resistance require a high level of inorganic materials, but at the same time, the requirements for hardware compatibility are also increased. On the other hand, fire doors that meet the aesthetic requirements of the general public cannot meet the safety requirements of high fire resistance. Fire doors face a dilemma. Summary of the Invention

[0004] The purpose of this invention is to provide an integrally molded hollow fireproof door leaf and its manufacturing process to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an integrally molded hollow fireproof door leaf, comprising a fireproof door leaf core, wherein gray silica plates are provided on both opposite sides of the fireproof door leaf core, the gray silica plates are provided in two layers, the surface of the gray silica plates away from the fireproof door leaf core is provided with a decorative surface layer, a hinge-side gray silica plate strip is provided between the two layers of gray silica plates at one end of the fireproof door leaf core, and a lightweight hollow channel is provided inside the fireproof door leaf core.

[0006] Preferably, a reinforcing layer is provided between the fireproof door core and the gray silica board, and the reinforcing layer is provided with a mesh structure woven from reinforcing ribs.

[0007] Preferably, the fireproof door leaf core is made of expanded EPS and air-foamed slurry, and the density of the fireproof door leaf core is 0.4-0.8 g / cm³. 3 The thickness of the fireproof door leaf core and the gray silica strip on the hinge side is 35mm, the width of the gray silica strip on the hinge side is 20mm, the thickness of the gray silica plate is 5mm, and several lightweight hollow channels are evenly spaced. The diameter of the lightweight hollow channel is 30mm, and the distance between two adjacent lightweight hollow channels is 40mm.

[0008] A process for integrally molded hollow fireproof door leaf, the process comprising the following steps: Step 1, Pulping: The raw materials are pulped according to the formula using a pulping machine to prepare the pulp precursor; Step 2, Slurry Storage: The slurry prepared by the pulping machine is stirred and diluted in a slurry storage tank to obtain slurry; Step 3: Granulation: Prepare EPS raw materials into EPS foam granules and store them in a storage silo; Step 4: Preparation of semi-finished boards: The slurry in the slurry storage tank is molded into boards to obtain semi-finished boards; Step 5: Mixing: Mix the slurry in the slurry tank and the EPS foam particles in the storage bin in a mixer according to the specified ratio to obtain the mixture; Step 6: Molding: The mixture and semi-finished board are shaped using a vertical molding die to obtain the fireproof door leaf.

[0009] Preferably, the specific operation steps of the pulping are as follows: S1. Decomposition: Wood fiber, pulping slurry and dispersing additives are prepared by decomposition machine to obtain wood fiber decomposed material; S2. Grinding and mixing: Kaolin, additives and inorganic adhesives are ground and mixed using a grinding and mixing machine to obtain kaolin grinding mixture; S3. Pulping: Pulping the wood fiber decomposed material and the kaolin grinding mixture in a pulping machine in a certain proportion to obtain the pulp precursor.

[0010] Preferably, the specific granulation operation steps are as follows: S1. Foaming: EPS raw materials are foamed using a foaming machine, and the EPS foamed particles are stored in the foaming silo. S2. Drying: The EPS foam particles are dried by passing them through a fluidized bed dryer to obtain EPS foam particles, which are then stored in a storage silo.

[0011] Preferably, the specific operational steps for preparing the semi-finished board are as follows: S1. Plate making: The slurry in the slurry storage tank is processed by a plate making machine to prepare plate blanks; S2. Cutting: The blank prepared by the plate making machine is fed into the cutting mold by the blank receiving machine for fixed length and width cutting. S3. Stacking: Stacking the cut slabs using a stacker crane; S4. Pressure forming: Pressure forming of stacked slabs using a pressure forming machine; S5. Demolding: The slab is demolded from the cutting die using a demolding machine; S6. Curing: Place the molded billet into the pre-curing kiln for steam curing; S7. Drying: The autoclaved slab is placed in a dryer for drying to obtain a semi-finished slab, namely the gray silica board for hollow fireproof door panels.

[0012] Preferably, the specific steps of the molding process are as follows: S1. Place the semi-finished board into the edge of the vertical forming mold and fix it in place; S2. Inject the mixture from the mixer into a vertical molding mold, that is, cast the fireproof door core between two layers of gray silicon board to prepare a hollow fireproof door. S3. Drying and Curing: The hollow fireproof door leaf is removed from the vertical forming mold, and then dried and cured to produce the finished hollow fireproof door leaf.

[0013] Preferably, the cutting mold after demolding by the demolding machine during the preparation of the semi-finished board is cleaned and returned to the blank receiving machine, and the residual material generated during the cutting process of the semi-finished board is recycled and sent to the slurry storage tank.

[0014] Preferably, after the semi-finished board is fixed by the edge of the vertical forming mold, the reinforcing layer woven with reinforcing ribs is laid and fixed along the semi-finished board, and the reinforcing layer is cast between the gray silicon board and the fireproof door core.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This one-piece molded hollow fireproof door leaf and its manufacturing process, through the use of gray silica board and fireproof door leaf core, meet the latest mandatory requirements for fireproof door raw materials, do not effloresce, and achieve A1 fire resistance performance with a very thin door body. The frame surface can be decorated, the door weight can be customized, the material density of the door core can be adjusted and controlled, and the reinforcing layer strengthens the structural strength of the door leaf, resulting in a stable structure, stable performance, and no deformation due to moisture.

[0016] This one-piece molded hollow fireproof door leaf and its manufacturing process achieve true one-piece molding, saving processes and labor, avoiding quality defects introduced during composite processes, eliminating the possibility of delamination between the door core and the surface panel, and the slurry and frame panel have similar raw material composition, which are bonded together during constant temperature and pressure drying, so the contact interface is firmly bonded, the hollow structure can reduce the weight of the door, and the hollow structure can produce a sound-absorbing effect, increasing the sound insulation effect. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0018] Figure 2 This is a schematic diagram of the structure of the fireproof door leaf core in this invention.

[0019] Figure 3 This is a process flow diagram of the hollow fireproof door leaf in this invention.

[0020] In the diagram: 1. Gray silica board; 2. Fire door leaf core; 3. Gray silica board strips on the hinge side; 4. Lightweight hollow channel; 5. Reinforcing layer. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] like Figures 1 to 3As shown, this embodiment of the integrally molded hollow fireproof door leaf includes a fireproof door leaf core 2. Both sides of the fireproof door leaf core 2 are provided with gray silica plates 1. The gray silica plates 1 are provided with two layers. The surface of the gray silica plate 1 away from the fireproof door leaf core 2 is provided with a decorative surface layer. A hinge-side gray silica plate strip 3 is provided between the two layers of gray silica plates 1 at one end of the fireproof door leaf core 2. The interior of the fireproof door leaf core 2 is provided with a lightweight hollow channel 4. The lightweight hollow channel 4 reduces noise and reduces the weight of the door leaf. According to the needs of heat preservation, sound insulation and other requirements of the door leaf, corresponding heat preservation layer and sound insulation layer can be added between the gray silica plate 1 and the fireproof door leaf core 2.

[0024] Specifically, a reinforcing layer 5 is provided between the fireproof door core 2 and the gray silicon board 1. The reinforcing layer 5 is set in a grid structure woven by reinforcing ribs. The reinforcing ribs are made of steel bars to enhance the structural strength of the door.

[0025] Furthermore, the fireproof door leaf core 2 is made of expanded EPS and air-foamed slurry, and the density of the fireproof door leaf core 2 is 0.4-0.8 g / cm³. 3 The thickness of the fireproof door leaf core 2 and the hinge side gray silica strip 3 is 35mm, the width of the hinge side gray silica strip 3 is 20mm, the thickness of the gray silica board 1 is 5mm, and several lightweight hollow channels 4 are evenly spaced. The diameter of the lightweight hollow channel 4 is 30mm, and the distance between two adjacent lightweight hollow channels 4 is 40mm. The fireproof door leaf structure is lightweight and uniform.

[0026] A process for one-piece molding of hollow fireproof door leaf, the process includes the following steps: Step 1, Pulping: The raw materials are pulped according to the formula using a pulping machine to prepare the pulp precursor; Step 2, Slurry Storage: The slurry prepared by the pulping machine is stirred and diluted in a slurry storage tank to obtain slurry; Step 3: Granulation: Prepare EPS raw materials into EPS foam granules and store them in a storage silo; Step 4: Preparation of semi-finished boards: The slurry in the slurry storage tank is molded into boards to obtain semi-finished boards; Step 5: Mixing: Mix the slurry in the slurry tank and the EPS foam particles in the storage bin in a mixer according to the specified ratio to obtain the mixture; Step 6: Molding: The mixture and semi-finished board are shaped using a vertical molding die to obtain the fireproof door leaf.

[0027] Furthermore, the specific procedures for pulping are as follows: S1. Decomposition: Wood fiber, pulping slurry and dispersing additives are prepared by decomposition machine to obtain wood fiber decomposed material; S2. Grinding and mixing: Kaolin, additives and inorganic adhesives are ground and mixed using a grinding and mixing machine to obtain kaolin grinding mixture; S3. Pulping: Pulping the wood fiber decomposed material and the kaolin grinding mixture in a pulping machine in a certain proportion to obtain the pulp precursor.

[0028] Furthermore, the specific granulation process is as follows: S1. Foaming: EPS raw materials are foamed using a foaming machine, and the EPS foamed particles are stored in the foaming silo. S2. Drying: The EPS foam particles are dried by passing them through a fluidized bed dryer to obtain EPS foam particles, which are then stored in a storage silo.

[0029] Furthermore, the specific operational steps for preparing the semi-finished board are as follows: S1. Plate making: The slurry in the slurry storage tank is processed by a plate making machine to prepare plate blanks; S2. Cutting: The blank prepared by the plate making machine is fed into the cutting mold by the blank receiving machine for fixed length and width cutting. S3. Stacking: Stacking the cut slabs using a stacker crane; S4. Pressure forming: Pressure forming of stacked slabs using a pressure forming machine; S5. Demolding: The slab is demolded from the cutting die using a demolding machine; S6. Curing: Place the molded billet into the pre-curing kiln for steam curing; S7. Drying: Place the autoclaved slab into a dryer for drying to obtain a semi-finished slab, namely the gray silica board 1 for hollow fireproof door leaf. Similarly, prepare the gray silica board strip 3 for the hinge side.

[0030] Furthermore, the specific molding process is as follows: S1. Place the semi-finished board into the edge of the vertical forming mold and fix it. Then, clip the gray silicon board strip 3 on the hinge side between the two gray silicon boards 1. S2. Inject the mixture in the mixer into the vertical molding mold, that is, cast the fireproof door core 2 between the two layers of gray silicon board 1 to prepare the hollow fireproof door. S3. Drying and Curing: The hollow fireproof door leaf is removed from the vertical forming mold, and then dried and cured to produce the finished hollow fireproof door leaf.

[0031] Furthermore, after the cutting mold is demolded by the demolding machine during the semi-finished board preparation process, it is cleaned and sent back to the blank receiving machine. The residual material generated during the cutting process of the semi-finished board preparation process is recycled and sent to the slurry storage tank. If crushed, the residual material is recycled and reused, saving energy.

[0032] Furthermore, after the semi-finished board is placed into the edge of the vertical forming mold and fixed, the reinforcing layer 5 woven with reinforcing ribs is laid and fixed along the semi-finished board. The reinforcing layer 5 is poured between the gray silicon board 1 and the fireproof door core 2.

[0033] The method of use in this embodiment is as follows: Wood fiber, pulping slurry, and dispersing additives are prepared using a disintegrator; kaolin, additives, and inorganic adhesives are ground and mixed using a grinding and mixing machine; the wood fiber disintegration material and kaolin grinding mixture are pulped in a pulping machine according to a certain ratio; the slurry prepared by the pulping machine is stirred and diluted in a slurry storage tank to obtain a slurry; EPS raw materials are foamed using a foaming machine; EPS foamed particles are dried using a fluidized bed dryer; the slurry in the storage tank is processed by a board-making machine to prepare board blanks; the board blanks prepared by the board-making machine are connected to a cutting die for fixed length and width cutting using a blank receiving machine; the cut board blanks are stacked using a stacking machine; the excess material generated from cutting is recycled and sent back to the slurry storage tank; the cut board blanks are stacked again using a stacking machine; the stacked board blanks are pressure-formed using a pressure forming machine; and the board blanks are then demolded using a demolding machine. The blank is demolded from the cutting mold, cleaned, and returned to the receiving machine. The demolded blank is then placed in a pre-curing kiln for autoclaving. The autoclaved blank is then dried in a dryer to obtain a semi-finished board, consisting of silica fume 1 and hinge-side silica fume strips 3. The semi-finished board is then fitted and fixed along the edge of a vertical forming mold. The hinge-side silica fume strips 3 are secured between the two silica fume 1s. A reinforcing layer 5, woven with reinforcing ribs, is laid and fixed along the semi-finished board. The mixture from the mixer is injected into the vertical forming mold, thus casting the fireproof door core 2 between the two silica fume 1s to produce a hollow fireproof door. The hollow fireproof door is then removed from the vertical forming mold, dried, and cured to produce the finished hollow fireproof door. In response to the new standard's raw material requirements, the raw materials used possess both fire resistance and low density (apparent density 0.7-1.0 g / m³). 3 Improve fire door performance and resistance to efflorescence; reduce overall fire door weight, reduce fire door lock load, and reduce fire door opening and closing force; reduce fire door processing steps and reduce adhesive usage during processing to ensure fire doors are both fireproof and environmentally friendly; reduce costs, improve door leaf manufacturability and designability, and increase applicable locations; reduce door leaf weight.

[0034] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A one-piece molded hollow fireproof door leaf, comprising a fireproof door leaf core (2), characterized in that: The fireproof door core (2) has gray silicon plates (1) on both sides. The gray silicon plates (1) have two layers. The surface of the gray silicon plates (1) away from the fireproof door core (2) has a decorative surface layer. A hinge side gray silicon plate strip (3) is provided between the two layers of gray silicon plates (1) at one end of the fireproof door core (2). The interior of the fireproof door core (2) has a lightweight hollow channel (4).

2. The one-piece molded hollow fireproof door leaf according to claim 1, characterized in that: A reinforcing layer (5) is provided between the fireproof door core (2) and the gray silicon board (1), and the reinforcing layer (5) is woven into a grid structure by reinforcing ribs.

3. The one-piece molded hollow fireproof door leaf according to claim 1, characterized in that: The fireproof door leaf core (2) is made of foamed EPS and air-foamed slurry, and the density of the fireproof door leaf core (2) is 0.4-0.8 g / cm³. 3 The thickness of the fireproof door core (2) and the hinge side gray silicon strip (3) is 35mm. The width of the hinge side gray silicon strip (3) is 20mm. The thickness of the gray silicon plate (1) is 5mm. Several lightweight hollow channels (4) are evenly spaced. The diameter of the lightweight hollow channel (4) is 30mm. The distance between two adjacent lightweight hollow channels (4) is 40mm.

4. A process for integrally molded hollow fireproof door leaf, characterized in that: The process includes the following steps: Step 1, Pulping: The raw materials are pulped according to the formula using a pulping machine to prepare the pulp precursor; Step 2, Slurry Storage: The slurry prepared by the pulping machine is stirred and diluted in a slurry storage tank to obtain slurry; Step 3: Granulation: Prepare EPS raw materials into EPS foam granules and store them in a storage silo; Step 4: Preparation of semi-finished boards: The slurry in the slurry storage tank is molded into boards to obtain semi-finished boards; Step 5: Mixing: Mix the slurry in the slurry tank and the EPS foam particles in the storage bin in a mixer according to the specified ratio to obtain the mixture; Step 6: Molding: The mixture and semi-finished board are shaped using a vertical molding die to obtain the fireproof door leaf.

5. The process for integrally molded hollow fireproof door leaf according to claim 4, characterized in that: The specific steps for pulping are as follows: S1. Decomposition: Wood fiber, pulping slurry and dispersing additives are prepared by decomposition machine to obtain wood fiber decomposed material; S2. Grinding and mixing: Kaolin, additives and inorganic adhesives are ground and mixed using a grinding and mixing machine to obtain kaolin grinding mixture; S3. Pulping: Pulping the wood fiber decomposed material and the kaolin grinding mixture in a pulping machine in a certain proportion to obtain the pulp precursor.

6. The process for integrally molded hollow fireproof door leaf according to claim 4, characterized in that: The specific granulation process is as follows: S1. Foaming: EPS raw materials are foamed using a foaming machine, and the EPS foamed particles are stored in the foaming silo. S2. Drying: The EPS foam particles are dried by passing them through a fluidized bed dryer to obtain EPS foam particles, which are then stored in a storage silo.

7. The process for the one-piece molded hollow fireproof door leaf according to claim 4, characterized in that: The specific operational steps for preparing the semi-finished board are as follows: S1. Plate making: The slurry in the slurry storage tank is processed by a plate making machine to prepare plate blanks; S2. Cutting: The blank prepared by the plate making machine is fed into the cutting mold by the blank receiving machine for fixed length and width cutting. S3. Stacking: Stacking the cut slabs using a stacker crane; S4. Pressure forming: Pressure forming of stacked slabs using a pressure forming machine; S5. Demolding: The slab is demolded from the cutting mold using a demolding machine; S6. Curing: Place the molded billet into the pre-curing kiln for steam curing; S7. Drying: The autoclaved slab is placed in a dryer for drying to obtain a semi-finished slab, namely the gray silica board for hollow fireproof door leaf (1).

8. The process for the one-piece molded hollow fireproof door leaf according to claim 4, characterized in that: The specific steps involved in the molding process are as follows: S1. Place the semi-finished board into the edge of the vertical forming mold and fix it in place; S2. Inject the mixture in the mixer into the vertical molding mold, that is, cast the fireproof door core (2) between the two layers of gray silicon board (1) to prepare the hollow fireproof door. S3. Drying and Curing: The hollow fireproof door leaf is removed from the vertical forming mold, and then dried and cured to produce the finished hollow fireproof door leaf.

9. The process for the integrally molded hollow fireproof door leaf according to claim 7, characterized in that: After the cutting mold is demolded by the demolding machine during the preparation of the semi-finished board, it is cleaned and returned to the blank receiving machine. The residual material generated during the cutting process of the semi-finished board is recycled and sent to the slurry storage tank.

10. The process for the integrally molded hollow fireproof door leaf according to claim 8, characterized in that: After the semi-finished board is fixed by the edge of the vertical forming mold, the reinforcing layer (5) woven with reinforcing ribs is laid and fixed along the semi-finished board. The reinforcing layer (5) is poured between the gray silicon board (1) and the fireproof door core (2).

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