Door leaf or door blank

Abstract

Door leaf or door blank (100, 102) - with at least one, in particular acoustic, core location (10, 12), - with at least one first chipboard layer (50) assigned to a surface of the core layer (10, 12), - with at least one of the core layer (10, 12) on its surface facing away from the first chipboard layer (50) assigned to the second chipboard layer (52), wherein at least one adhesive area (20) is provided on the mutually facing surfaces of the core layer (10, 12) and / or the chipboard layers (50, 52) in which the mutually facing layers (50; 10, 12; 52) are bonded or glued together, in particular by means of urea-formaldehyde adhesive (KUF) or melamine-urea-formaldehyde adhesive (MUF).

Description

Technical FieldThe present invention relates to the technical field of door panels or door blanks, in particular for at least one fire protection door or for at least one fire protection door or for at least one smoke protection door.Prior ArtDoor panels or door blanks frequently have a relatively high sound permeability and insufficient fire protection properties. It has been found, for example, that door leaves or door blanks are subjected to severe twisting in the event of a fire, so that--also for weight reasons--frequently larger formats are prohibited.Preparation of the present invention:Object, Solution, Advantages and Preferred Embodiments of the Present InventionProceeding from the disadvantages and deficiencies set forth above and in light of the outlined prior art, the object of the present invention is to provide a door leaf or a door blank which is distinguished both by high air-sound insulation and by very good fire protection properties.This object is achieved by a door leaf or by a door blank having the features of claim 1. Advantageous embodiments and practical further developments of the present invention are characterized in the respective dependent claims.According to the invention, the door leaf or the door blank is provided:having at least one, in particular acoustic, core layer,having at least one first chip board layer assigned to a surface of the core layer,having at least one second chipboard layer assigned to the core layer on its surface facing away from the first chipboard layer,wherein at least one adhesive region is provided on the mutually facing surfaces of the core layer and / or of the chipboard layers, in which the mutually facing layers are bonded or glued to one another, in particular by means of urea-formaldehyde adhesive (KUF) or melamine-urea-formaldehyde adhesive (MUF).According to a preferred embodiment of the present invention, the core layer can be designed as at least one core layer, in particular as at least one planar insulation panel, for exampleas at least one rock wool plate oras at least one composite plate made of rock wool and at least one other material.The core layer can advantageously be designed as an insulating core with a thickness of about ten millimeters to about 45 millimeters.According to a suitable embodiment of the present invention, two or more core layers can be provided and the core layers have a different density, for example in such a way that approximately 45 percent of an acoustic core layer of low density and approximately 55 percent of an acoustic core layer of high density can be arranged as starting material in the interior of the door leaf or door blank.Preferably, in the case of two or more core layers, the glue may be introduced between the first core layer and the second core layerbased on polyurethane (PU), ora heat-resistant white or starch glue or a low-formaldehyde dispersion glue, in particular based on PVAc (polyvinyl acetate) as binder.If the at least one core layer is formed from two or more parts or is constructed from two or more partial elements, then at least one joint can advantageously be arranged within the at least one core layer in the transition region between the parts or partial elements.According to a suitable embodiment of the present invention, the at least one core layer, in particular the region between core layer and chipboard layer, for example close to the at least one joint, can be assigned at least one intumescent coating or at least one intumescent region, in particular at least one intumescent strip or at least one intumescent strip, for example based on graphite or carbon.In a preferred embodiment, the first chipboard layer and / or the second chipboard layer can be formed as at least one particle board, as at least one medium-density fibre board, as at least one veneer layer or as at least one plywood layer, in particular as at least one poplar plywood layer, for example with a density of more than about 450 kg / m 3 to 480 kg / m 3, such as with a density of more than about 700 kg / m 3.The first dieboard layer and / or the second dieboard layer may have a respective thickness of about fifteen millimeters to about thirty millimeters.According to an advantageous embodiment of the present invention, at least one flame retardant can be added to the material of the first chipboard layer and / or to the material of the second chipboard layer, in particular the material of the first chipboard layer and / or the material of the second chipboard layer can be impregnated with the at least one flame retardant.In an expedient development of the present invention, the first chipboard layer, in particular the surface of the first chipboard layer facing away from the core layer, and / or the second chipboard layer, in particular the surface of the second chipboard layer facing away from the core layer, can be provided, in particular laminated or bonded, with at least one surface finish or finish, in particular with at least one cover layer, for example with at least one medium-tight fibre board or M[edium]D[ensity]F[ibreboard].According to a preferred embodiment of the present invention, the at least one adhesive region can be bondedcontinuous from one outer edge of the door leaf or door blank to another, in particular the opposite, outer edge of the door leaf or door blank, or- can be formed partially or partially, in particular pointwise or pointwise.Independently thereof or in conjunction therewith, the at least one adhesive region can be bondedas an adhesive or glue joint, in particular at least partially circular or meandering or serpentine or extending in a straight line, and / ordiagonally with respect to the outer edges of the door leaf or door blank.In the case of two or more adhesive regions, in an advantageous development of the present invention, the adhesive regions can be arranged offset from one another from layer to layer, in particular at equal distances from one another or at irregular distances from one another.The present invention finally relates to the use of at least one door leaf or door blank, in particular designed in the manner of a sandwich panel or sandwich panel, according to the type set forth above for at least one wood door, in particular for at least one fire protection door or for at least one fire protection door or for at least one smoke protection door.Brief Description of the DrawingsAs already discussed above, there are various possibilities for advantageously embodying and developing the teaching of the present invention. In this regard, reference is made on the one hand to the claims subordinate to claim 1, and on the other hand further embodiments, features and advantages of the present invention are explained in more detail below, inter alia, on the basis of the exemplary embodiments illustrated by FIGS. 1A to 3G, wherein any dimension specifications and / or any type specifications / brand specifications relating in particular to MMG are to be understood purely by way of example, in particular not by way of limitation.It shows: FIG. 1A is a horizontal cross-sectional view of a first embodiment of a door leaf or door blank according to the present invention; FIG. 1B is a vertical cross-sectional view of the first exemplary embodiment from FIG. 1A ; FIG. 1C shows a perspective top view of the first exemplary embodiment from FIGS. 1A and 1B ; FIG. 1D shows a partially cut-away perspective view of the first exemplary embodiment from FIGS. 1A, 1B and 1C ; FIG. 2A is a horizontal cross-sectional view of a second embodiment of a door leaf or door blank according to the present invention; FIG. 2B shows a vertical cross-sectional view of the second exemplary embodiment from FIG. 2A ; FIG. 2C shows a perspective top view of the second exemplary embodiment from FIGS. 2A and 2B ; FIG. 2D shows a partially broken-off perspective view of the second exemplary embodiment from FIGS. 2A, 2B and 2C ; FIGS. 3A to 3G show various design, installation and / or processing situations of the first exemplary embodiment (cf. FIGS. 1A, 1B, 1C, 1D ), namely as an overview in plan view (cf. FIG. 3A ), in cross section (cf. FIGS. 3B, 3C ), in horizontal cross section (cf. FIG. 3D ), in vertical cross section (cf. FIG. 3E ), in cross section on the hinge side (cf. FIG. 3F ) and in cross section on the lock side (cf. FIG. 3G ).Identical or similar configurations, elements or features are provided with identical reference numerals in FIGS. 1A to 3G.Embodiments, particularly best mode for carrying out the present inventionAs a door leaf or door blank (=reference sign 100 in FIGS. 1A, 1B, 1C, 1D ; reference sign 102 in FIGS. 2A, 2B, 2C, 2D ) a sandwich panel or sandwich panel is provided which expands a plurality of layers or layers as follows:The core layer, in particular acoustic core layer, also referred to as an insulating core or insulation core, can have a thickness of about ten millimeters to about fifteen millimeters, in particular a thickness of about eleven millimeters to about fourteen millimeters, and ensures good sound insulation of the door:This may be an insulating panel 10 (cf. first exemplary embodiment according to FIGS. 1A, 1B, 1C, 1D ) or two insulating panels 10, 12 assigned to one another (=second exemplary embodiment according to FIGS. 2A, 2B, 2C, 2D ); more than two insulating panels may also be provided.The insulation panel 10, 12 can be designed, for example, as at least one rock wool panel and, in the exemplary embodiments shown, functions as an insulation core, especially for wood doors. The insulating core can also have a composite of rock wool and other lasting materials which enables very good sound-absorbing properties (up to about 43 dB, depending on the core layer / s / s and on the density) in conjunction with excellent fire performance (class EI30 to about EI90, wherein a stable door construction is advisable) and excellent heat insulation with good thermal conductivity.If the insulating core is composed, for example for reasons of size, of two or more such insulating core elements or components or parts, at least one joint 30, 32 (so-called butt joint) can be located in each case between the individual insulating panel elements or components or parts.For example, in the region of these joint joints 30, 32, the at least one intumescent coating or at least one intumescent region 40, 42 (so-called intumescent strip) can be arranged. This realizes a flexible and intumescent fire protection seal, for example based on graphite or carbon.Upon exposure to fire, the intumescent material expands. Such expansion produces a microporous layer which prevents the passage of flames, smoke or hot gases, which also contributes to the excellent fire performance of the embodiments of the present invention.The intumescent coating 40, 42 has the property of swelling under the action of heat and forming a thermally insulating foam layer which can protect the material located underneath from excessive heat.In some cases, however, the inflation of the fire protection compound also achieves sealing of, for example, joints, so that flame escape is prevented and toxic combustion gases can no longer escape or else oxygen supply from the outside is prevented.Not least in view of its mechanical properties and its surface hardness as well as dimensional stability, the insulating core can be designed as a single-layer plate (cf. first exemplary embodiment according to FIGS. 1A, 1B, 1C, 1D ), as a two-layer plate (cf. second exemplary embodiment according to FIGS. 2A, 2B, 2C, 2D ) or as a multi-layer plate with a full-core thickness of only about ten millimeters to about 45 or even fifty millimeters with very tight thickness tolerances.The insulating core is terminated on both sides by a respective chipboard layer 50, 52. The chipboard layer 50, 52 may have a thickness of about 15 millimeters to about 25 millimeters, in particular of about 16 millimeters to about 22 millimeters, and may be formed from at least one chip board.The chip board layer 50, 52 can have particular properties, for example in the form of at least one additive:Such an additive can be realized, for example, in the form of at least one flame retardant with which the chipboard layer 50, 52 can be provided in order to have improved fire protection properties, that is to say the chipboard layer 50, 52 becomes flame-resistant due to the additive.It is also possible for the material of the chipboard layer 50, 52 to be highly compacted in order to increase the stability and load-bearing capacity of the door leaf or door blank 100 or 102.Independently thereof or in conjunction therewith, the chipboard layer 50, 52 can be provided with at least one surface finish or surface finish 60, 62 in order to increase the surface finish of the chipboard layer 50, 52, for example in the manner of a M[edium]D[ensity]F[ibreboard]-Platte or medium-density fibre board.Thus, in particular on the surface of the chipboard layer 50, 52 facing away from the core layer 10, 12, at least one M[edium]D[ensity]F[ibreboard]-Deckschicht 60, 62 (so-called MDF deck) can be provided, which (the) is laminated or adhesively bonded onto the chipboard layer 50, 52.As a result, the chipboard layer 50, 52, optionally provided with at least one additive, in particular impregnated, can therefore be laminated or bonded to its exposed outer side (=on its surface facing away from the core layer 10, 12) for the purpose of surface finishing or surface finishing with M[edium]D[ensity]F[ibreboard].A layer or layer structure of the chipboard layer 50, 52 is therefore also conceivable, for example in the form of a coarser layer or layer which is surrounded on both sides by a respective finer layer or layer, wherein the material of the finer layer or layer can also be wood-fibre-like, for example on M[edium]D[ensity]F[ibreboard]-Basis for optical reasons.The individual plies or layers are bonded or glued to one another in respective adhesive regions 20. For the permanent and firm connection of the individual plies or layers of the door leaf or door blank 100, 102, adhesive regions 20 are thus provided on the surface of these plies or layers. In this case, the arrangement of these adhesive regions 20 from layer to layer is decoupled from one another, so that these adhesive regions 20 are arranged from layer to layer with a defined offset, i.e. offset, with respect to one another, in order to achieve a particularly permanent and firm connection of the individual layers.As can be seen from the illustration in FIG. 1D (=first exemplary embodiment) and in FIG. 2D (=second exemplary embodiment), these adhesive regions 20 can be formed in particular as so-called glue lines, for example approximately 300 millimeters apart from one another, that is to say as adhesive or glue joints, wherein the offset of the adhesive regions 20 with respect to one another can be formed in a regular manner, that is to say at the same distance from one another, or in an irregular manner, that is to say not at the same distance from one another.In an advantageous embodiment, the adhesive regions 20 can be arranged on the layer surface diagonally, i.e. neither parallel nor perpendicular with respect to the outer edges of the door leaf or door blank 100, 102.Independently of this or in conjunction therewith, it is also conceivable for the adhesive regions 20 not to be designed as straight-line adhesive or glue joints, but instead, for example, to be at least partially circular or meandering or serpentine.The adhesive regions 20 can, as shown in FIG. 1D (=first exemplary embodiment) and in FIG. 2D (=second exemplary embodiment), be configured continuously from one outer edge of the door leaf or door blank 100, 102 to another outer edge, in particular the opposite outer edge, of the door leaf or door blank 100, 102.However, it is also possible in a relevant manner to design the adhesive regions 20 only in sections or only partially, for example also only at points or pointwise, in order to save adhesive or glue with a permanent and firm connection of the individual layers or layers of the door leaf or door blank 100, 102 that is still achievable.In a particularly advantageous manner, at those locations at which such an adhesive region 20 is provided on a layer or layer of the door leaf or door blank 100, 102, no adhesive region is provided on the layer or layer adjoining or adjacent to this layer or layer, so that in a partially cut-away plan view (cf., for example, the representation according to the first exemplary embodiment in FIG. 1D or the representation according to the second exemplary embodiment in FIG. 2D ) a quasi-concertina-like offset of the respective adhesive regions 20 results.The way in which the individual plies or layers are glued, in particular by the pattern, effected by means of the respective adhesive regions 20, enables the acoustic protection to be improved significantly, for example to a cemented value of 46 dB for double-leaf doors (since sound behaves logarithmically, in this order of magnitude means an increase of approximately 3 dB means a doubling of the acoustic power).Due to the very high stability in the event of a fire, the door leaf or the door blank 100, 102 according to FIGS. 1A to 3G is also suitable in particular as a smoke protection door. Overall, therefore, the present invention provides a surprisingly simple, normally flammable, large-format fire door or fire door and smoke protection door with low waviness on its surface with excellent stability in the event of a fire.The door leaf or door blank 100, 102 according to the present invention serves to provide a door system made of wood in the areas of training, recreational, health, industrial, hotel, media, broadcasting and residence, as well as in all other living areas with high noise protection requirements. The door system enables the highest possible comfort and good operation.Possible design, installation and / or processing situations of the door system are illustrated with reference to FIG. 3A (= Überblick), FIG. 3B (Solid Timer Insert= Massiv wood insert), FIG. 3C (= Vertikale Vertical and Horizontal Cross-Sectional Views) and FIG. 3D (= Querschnitt Cross-Sectional View on the hinge side and on the lock side).The door leaf or the door blank 100, 102 according to FIGS. 1A to 3G can be easily processed by milling and / or by folding and is suitable as veneer and can be coated with laminate. The door leaf or the door blank 100, 102 according to FIGS. 1A to 3G have a very high stability and very smooth surfaces with a high acoustic damping effect.Conceivable exemplary constructions are single-leaf or two-leaf door elements, each in the form of a solid leaf or glazed, with or without an overhead light and / or glazed side part, suspended in a block frame.List of reference characters100 Door leaf or door blank (cf. first exemplary embodiment according to FIGS. 1A, 1B, 1C, 1D ) 102 door leaf or door blank (cf. second exemplary embodiment according to FIGS. 2A, 2B, 2C, 2D ) 10 core layer, in particular first core layer 12 second core layer 20 adhesive region 30 joint joint of the, in particular first, core layer 10 32 joint of the second core layer 12 40 intumescent coating or intumescent region of the, in particular first, core layer 10 42 intumescent coating or intumescent region of the second core layer 12 50 chipboard layer, In particular, first chipboard layer 52 second chipboard layer 60 surface finish or surface finish of first chipboard layer 50 62 surface finish or surface finish of second chipboard layer 52

Claims

Door leaf or door blank (100, 102) - with at least one, in particular acoustic, core layer (10, 12), - with at least one first chipboard layer (50) assigned to a surface of the core layer (10, 12), - with at least one second chipboard layer (52) assigned to the core layer (10, 12) on its surface facing away from the first chipboard layer (50), wherein at least one adhesive region (20) is provided on the mutually facing surfaces of the core layer (10, 12) and / or of the chipboard layers (50, 52), in which the mutually facing layers (50; 10, 12; 52) are bonded or glued to one another, in particular by means of urea-formaldehyde adhesive (KUF) or melamine-urea-formaldehyde adhesive (MUF).Door leaf or door blank according to claim 1, wherein the core layer (10, 12) is formed as at least one core layer, in particular as at least one planar insulation panel, for example - as at least one rock wool panel or - as at least one composite panel made of rock wool and at least one other material.Door leaf or door blank according to claim 1 or 2, wherein the core layer (10, 12) is designed as an insulating core having a thickness of about ten millimetres to about 45 millimetres.Door leaf or door blank according to at least one of Claims 1 to 3, characterized in that two or more core layers (10, 12) are provided and the core layers (10, 12) have a different density.Door leaf or door blank according to at least one of Claims 1 to 4, characterized in that two or more core layers (10, 12) are provided and the glue between the first core layer (10) and the second core layer (12) - is based on polyurethane (PU) or - is a heat-resistant white or starch glue or low-formaldehyde dispersion glue, in particular based on PVAc (polyvinyl acetate) as binder.Door leaf or door blank according to at least one of claims 1 to 5, wherein the at least one core layer (10, 12) is formed from two or more parts or is constructed from two or more partial elements and at least one joint (30, 32) is arranged within the at least one core layer (10, 12) in the transition region between the parts or partial elements.Door leaf or door blank according to at least one of claims 1 to 6, wherein the at least one core layer (10, 12), in particular the region between core layer (10, 12) and chipboard layer (50, 52), for example close to the at least one joint joint (30, 32), is assigned at least one intumescent coating or at least one intumescent region (40, 42), in particular at least one intumescent strip or at least one intumescent strip, for example based on graphite or carbon.Door leaf or door blank according to at least one of claims 1 to 7, wherein the first chipboard layer (50) and / or the second chipboard layer (52) are formed as at least one particle board, as at least one medium-density fibre board, as at least one veneer layer or as at least one plywood layer, in particular as at least one poplar plywood layer, for example with a density of more than about 450 kg / m 3 to 480 kg / m 3, such as with a density of more than about 700 kg / m 3.The door leaf or door blank according to at least one of claims 1 to 8, wherein the first chipboard layer (50) and / or the second chipboard layer (52) have a respective thickness of about fifteen millimeters to about thirty millimeters.Door leaf or door blank according to at least one of Claims 1 to 9, wherein at least one flame retardant is added to the material of the first chipboard layer (50) and / or to the material of the second chipboard layer (52), in particular the material of the first chipboard layer (50) and / or the material of the second chipboard layer (52) is impregnated with the at least one flame retardant.Door leaf or door blank according to at least one of Claims 1 to 10, wherein the first chipboard layer (50), in particular the surface of the first chipboard layer (50) facing away from the core layer (10, 12), and / or the second chipboard layer (52), in particular the surface of the second chipboard layer (52) facing away from the core layer (10, 12), is provided, in particular laminated or bonded, with at least one surface finish or finish (60, 62), in particular with at least one cover layer, for example with at least one medium-density fibre board or M[edium]D[ensity]F[ibreboard].Door leaf or door blank according to at least one of claims 1 to 11, wherein the at least one adhesive region (20) is - continuous from one outer edge of the door leaf or door blank (100, 102) to another, in particular the opposite, outer edge of the door leaf or door blank (100, 102) or - partially or partially, in particular pointwise or pointwise.Door leaf or door blank according to at least one of claims 1 to 12, wherein the at least one adhesive region (20) - is formed as an adhesive or glue joint, in particular at least partially circular or meandering or serpentine or extending in a straight line, and / or - is arranged diagonally with respect to the outer edges of the door leaf or door blank (100, 102).Door leaf or door blank according to at least one of claims 1 to 13, wherein two or more adhesive regions (20) are provided and the adhesive regions (20) are arranged offset from one another from layer (50; 10, 12; 52) to layer (50; 10, 12; 52), in particular at equal distances from one another or at irregular distances from one another.Use of at least one door leaf or door blank (100, 102) according to at least one of claims 1 to 14, in particular designed in the manner of a sandwich panel or sandwich panel, for at least one wood door, in particular for at least one fire protection door or for at least one fire protection door or for at least one smoke protection door.

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