DOOR LEAF, ESPECIALLY FIRE-RESISTANT DOOR LEAF

Abstract

Door leaf (10) in box-and-lid construction, in particular a fire-resistant door leaf, with a first and a second metal sheet element (12, 14), each formed from a metal sheet, which together enclose a door leaf cavity (20), and with a filling (22) inserted into the door leaf cavity (20), wherein on at least one narrow end face (26, 28, 30) of the door leaf (10), edge regions (88, 90) of the metal sheet elements (12, 14) form a side cavity (66) extending in the longitudinal direction of the at least one narrow end face (26, 28, 30), encompassed by the edge regions (88, 90), which is filled with a filling material (74) which is a poorer thermal conductor than the metal sheet, wherein the edge regions (88, 90) of the metal sheet elements surrounding the side cavity (66) (12, 14), without the sheet metal elements (12, 14) directly touching each other, are indirectly connected to each other via the filling material (74),wherein the side cavity (66) is filled with a filling element (64) comprising a first strip (70) of thermal insulation material (60) and a second strip (72) of thermal insulation material (60) as filling material (74), and additionally a reinforcing strip (76) embedded between the first strip (70) and the second strip (72), wherein the side cavity (66) is entirely enclosed by a C-profile structure (80) formed by the edge regions (88, 90) of the sheet metal elements (12, 14), and wherein additional strips (152) of thermal insulation material (60) are arranged around the C-profile structure (80) between the C-profile structure (80) and the regions of the sheet metal elements (12, 14) forming the door leaf broad sides (24, 58).

Description

[0001] The invention relates to a door leaf in box-cover construction.

[0002] In particular, the invention relates to a door leaf formed from sheet metal elements in the form of a box sheet and a cover sheet. In particular, the door leaf is designed as a fire-resistant door leaf.

[0003] AT 382 426 B describes a door leaf in a box-and-cover design, wherein a box sheet and a cover sheet do not touch, but are arranged with gaps between them. The door leaf has a C-profile structure in the edge region. The cover sheet protrudes beyond the box sheet and is bent twice to form a protruding door rebate. In the space created by the bend at the edge region of the box sheet, a multi-layer fire protection sealing strip for the door leaf rebate is inserted. This sealing strip is formed from at least one layer of a fire-resistant material, such as asbestos, and at least one layer of a material that expands under the influence of heat, such as sodium silicates, which are provided alternately with one another.

[0004] DE 77 079 23 U also discloses a door leaf formed from two metal sheets with U-shaped webs facing each other at their edges. These webs serve as reinforcement profiles and are, for example, rolled, riveted, or welded and connected to each other without contact using plastic profiles. This creates a double-leaf door leaf that is thermally insulated and thermally separated by inserting plastic profiles and asbestos.

[0005] DE 37 12 737 A1 discloses a fire door with a door leaf made of interconnected sheet metal panels forming a flat box. A stiffening frame composed of strips and an insulating insert are arranged within the box. The strips are covered by sheet metal strips running perpendicular to the plane of the door leaf. The strips are made of a material containing an evaporating liquid. The sheet metal strips are angled at least twice and cover the strips on at least three sides.

[0006] DE 24 49 232 A1 discloses a door leaf of a fire door with a frame whose frame strips consist of asbestos silicate strips that are perpendicular to the plane of the door leaf and connected to one another, with thin sheet metal strips being arranged between at least some of the asbestos silicate strips of the frame strips.

[0007] The object of the invention is to design a door leaf in box-cover construction which can also be designed as a fire-resistant door leaf, is thermally separated and has a high thermal insulation capacity, can be produced cost-effectively in large series and has an increased rigidity.

[0008] To achieve this object, the invention proposes a door leaf having the features of claim 1.

[0009] Advantageous embodiments of the invention are the subject of the subclaims.

[0010] According to a first aspect, the invention provides a door leaf in box-and-lid construction, in particular a fire-resistant door leaf, with a first and a second metal sheet element, each formed from a metal sheet, which together enclose a door leaf cavity, and with a filling inserted in the door leaf cavity, wherein on at least one narrow end face of the door leaf, edge regions of the metal sheet elements form a side cavity extending in the longitudinal direction of the narrow end face, encompassed by the edge regions, which is filled with a filling material which is a poorer thermal conductor than the metal sheet, wherein the edge regions of the metal sheet elements surrounding the side cavity are indirectly connected to one another via the filling material, without the metal sheet elements directly touching one another.

[0011] It is provided that the filling material has a first strip of thermal insulation material, a second strip of thermal insulation material and a reinforcing strip in between.

[0012] It is preferred that the reinforcing strip is formed from metal and is formed with a smaller width than the strips of thermal insulation material, wherein the strips of thermal insulation material preferably protrude beyond the reinforcing strip on both sides.

[0013] It is particularly preferred that the edge region of at least one of the sheet metal elements forms a U-profile which adjoins a profile region of the sheet metal element, which forms part of the narrow end face and extends in a thickness direction of the door leaf, preferably formed by a double fold, inwards towards the door leaf cavity.

[0014] It is preferably provided that both the edge region of the first metal sheet element and the edge region of the second metal sheet element are formed in a U-profile manner with U-profile grooves open to one another, so that the U-profile grooves together form the side cavity.

[0015] According to the invention, the side cavity is entirely enclosed by a C-profile structure formed by the edge regions of the sheet metal elements. Additional strips of thermal insulation material are arranged around the C-profile structure.

[0016] It is preferred that the edge regions of the sheet metal elements have sequences of projections and recesses that are complementary to one another, viewed in the narrow end-side longitudinal direction, wherein the projections of one sheet metal element engage with the recesses of the other sheet metal element without contact, in particular with a distance.

[0017] It is particularly preferred that the succession of projections and recesses is formed by rectangular or trapezoidal notches on the outermost edge strips of the metal sheets forming the metal sheet elements.

[0018] In an advantageous embodiment, it is provided that the projections are each fastened to the filling material by at least one fastening element, in particular a screw, more particularly a drilling screw.

[0019] It is preferably provided that the filling material comprises at least one strip of mineral-based fire protection material, in particular of mineral fiber board or of a vermiculite material.

[0020] According to a preferred embodiment of the invention, the front side cavity is formed by repeatedly bending the edge regions.

[0021] It is preferred that the narrow-end side cavity filled with the filling material is open to the outside through a gap extending over the narrow end, the width of which is smaller, in particular at least half smaller, than the extension of the side cavity in the thickness direction.

[0022] It is particularly preferred that the filling in the door leaf cavity is formed by a mineral fiber board and that the filling and the sheet metal elements are connected to one another in a materially bonded manner over a large area, in particular are glued to one another over a large area.

[0023] It is preferably provided that at least the two narrow end faces to be arranged vertically and one narrow end face to be arranged horizontally at the top are each formed with the side cavity extending longitudinally over the entire narrow end face.

[0024] It is further preferred that a side cavity is provided on each of the narrow end faces longitudinally over their entire extent, wherein the filling material in the respective first side cavity of the narrow end faces to be arranged vertically is overlapped on the outside by the edge regions of both the first and the second sheet metal element, while a second side cavity of a narrow end face to be arranged horizontally at the bottom is encompassed on the outside only by the edge region of only one of the sheet metal elements, wherein a lower door groove is formed between the lower side cavity and the main extension plane of the other sheet metal element.

[0025] Embodiments of the door leaf according to the invention can be produced by a method for producing such a door leaf, in particular a thermally separated one, which comprises the steps: a) providing a first metal sheet for forming the first metal sheet element and a second metal sheet for forming the second metal sheet element, c) folding the edge areas of the metal sheets to form a U-profile structure, d) Folding the entire U-profile structure and pressing it to form a double fold which forms part of the outer narrow face surface.

[0026] A particularly preferred embodiment of the method is characterized by the step to be carried out before step c): b) notching edge regions of the metal sheet panels to be formed in order to create a sequence of projections and recesses running along the edge, wherein the sequences of projections and recesses on the first and second metal sheets are complementary to one another.

[0027] A particularly preferred embodiment of the method is characterized by the steps: e) Inserting a filling element into the U-profile structure, f) Inserting and gluing a filling into a door leaf cavity remaining between the U-profile structures of the first metal sheet element, g) Place and glue the second metal sheet element onto the filling.

[0028] According to a preferred embodiment, one aim of the design is to achieve the most complete thermal separation possible between a box panel and a cover panel of a door leaf. For this purpose, strips of mineral panel, in particular strips of vermiculite panel (for example Thermax® strips) with sheet metal strips in between are used. Preferably, a new, special edge geometry of the box panel and cover panel is created. In a particularly preferred embodiment, the edges of both the box panel and the cover panel are bent over several times so that the strip of filler material is only accessible from the outside through a small gap. In order to create a receiving area for the strip of filler material, as seen from the outside from the outer surface of the front side inwards, there is first a complete fold of the panels, then a U-profile with two U-legs connected by a web.A U-leg is part of a double fold that forms a profile area for creating the outer end face. One web is preferably designed to extend inwards, parallel to the wide surface of the door leaf; this is followed by the further U-leg, which is formed from the outermost edge strip that forms the edge of the sheet metal panel. This free end region of the U-profile is preferably notched. Preferably, a series of projections and recesses is created here. Preferably, corresponding U-profile structures are formed on both the box sheet and the cover sheet, which are arranged in mirror image to one another and thus extend towards one another with their U-profile grooves. The projections and recesses on the free U-webs are designed to be complementary and interlock when the metal sheets are assembled.As a result, the two U-profile structures create a C-profile structure, with the gap being open to the outside and the side cavity thus formed being separated from the door leaf cavity by the interlocking U-webs.

[0029] One design features rectangular notches on the box plate and cover plate, which then alternately interlock. The box plate and cover plate are connected by strips of filler material inserted into the resulting side cavity.

[0030] Preferably, the filler material itself is formed from several strips of mineral board with a piece of sheet metal in between. Such a central piece of sheet metal between strips of thermally insulating material, which is inserted into the side cavity, further increases the rigidity of the front broadside profile.

[0031] According to a particularly preferred embodiment, neither the box sheet, nor the cover sheet, nor the sheet metal strip located therebetween touch each other.

[0032] Fastening is preferably carried out using fastening elements such as screw elements.

[0033] Overall, this results in thermal separation and yet a very rigid construction.

[0034] There are various approaches to the alternating, interlocking notches. One solution is a rectangular notch. Another solution would be a type of trapezoidal notch, creating dovetail structures. Overall, the sheets can engage behind each other with such notches. With such a dovetail notch or another notch with a rear grip, the sheets can hook behind each other, thus providing additional stiffening, particularly in the event of a fire.

[0035] Preferably, the previously explained design with a C-profile structure, which is formed by two U-profile structures arranged in mirror image to each other at the edge regions of the sheet metal elements, is formed on the vertically arranged narrow end faces (lock side and hinge side) and on the narrow end face arranged horizontally at the top. A different construction is preferably provided on the narrow end face arranged horizontally at the bottom, in particular in order to create a downwardly open door groove, for example for accommodating smoke protection seals or soundproofing materials. In a preferred embodiment, only the box sheet is bent around filler material in the lower region. Here, only a strip of filler material can be provided, i.e. without the interposition of another sheet metal strip.If the box sheet is connected to the cover sheet through a strip of filler material with a metal screw, a ring of thermally insulating material is preferably inserted below the screw head to achieve complete thermal separation. In such a construction, where connections in the top and side end areas are made only over the filler material and where thermal bridges are created at the bottom by washers made of thermally insulating material, complete thermal separation between the box sheet and cover sheet can be achieved.

[0036] The preferred edge geometry with an inwardly extending U-profile can be achieved using cold forming machines, such as roll formers with multiple rolling tools. The aforementioned double fold can be achieved, for example, by gripping the profile structure from behind and pressing it from behind.

[0037] A preferred method for producing the edge geometry involves folding from the outside in. First, the notches are made on the sheets to create the sequence of projections and recesses. Then, the notched sheets are folded, then the U-shaped webs and U-shaped legs are folded, and finally, the double fold is performed with pressing.

[0038] Bonding is preferred for joining the panel and metal sheets. Preferably, the panel filling is essentially formed by a mineral fiberboard, which is bonded over a large area to the inner surfaces of the door leaf's broad sides. This means that the door leaf is not only stiffened by stiffening folds on the end faces; the main part of the stiffening is achieved by the sandwich construction of the superimposed and bonded layers. Due to the large-area or full-surface bonding, the door leaf construction is inherently very rigid, eliminating the need for additional metal rods at the edges.

[0039] It should be noted that in the event of a fire, very high bending moments act on the door leaves of fire doors. In a fire, one of the broad sides of the door leaf becomes very hot, while the other broad side has a much lower temperature, leading to uneven expansion of the metal sheets and, in the event of a fire, to bending. However, thanks to the multiple folds and the sandwich construction with layers bonded together, lying on top of each other, this can be easily managed without the need for additional stiffening elements.

[0040] Embodiments of the invention are explained in more detail below with reference to the accompanying drawings, in which: Fig. 1 a front view of a door leaf broadside of an embodiment of a door leaf; Fig. 2 a view of the lock-side narrow end of the door leaf from the left in Fig. 1 seen; Fig. 3 a view of the hinge-side narrow end face of the door leaf from the right in Fig. 1 seen; Fig. 4 a plan view of the upper narrow face of the door leaf from above in Fig. 1 seen; Fig. 5 a view of the lower narrow end face of the door leaf from below in Fig. 1 seen; Fig. 6 a detailed view of detail VI in Fig. 3; Fig. 7 a horizontal section along the line VII-VII through the door leaf of Fig. 1; Fig. 8 a detailed view of detail VIII of Fig. 7; Fig. 9 a detailed view of detail IX of Fig. 7; Fig. 10 a vertical section along the line XX through the door leaf of Fig. 1; Fig. 11 an enlarged detail view of detail XI of Fig. 10; Fig. 12 an enlarged detail view of detail XII of Fig. 10; Fig. 13 a view from the inside of a door leaf cavity of Fig. 1 without filling along the line XIII-XIII in Fig. 1; Fig. 14 a part of section XIV-XIV of Fig. 1 without filling of the door leaf; Fig. 15 is an exploded perspective view of the door leaf of Fig. 1 with the individual parts of the door leaf; Fig. 16 an enlarged area from the illustration of Fig. 15, which shows the lower hinge-side area of ​​a box plate of the door leaf in more detail; Fig. 17 an enlarged area of ​​the display of Fig. 15 in the area of ​​the upper narrow end face of the box-type sheet metal construction; Fig. 18 an enlarged area of ​​the display of Fig. 15 in the area of ​​the lower lock side of the box construction; and Fig. 19 an enlarged area of ​​the display of Fig. 15, which represents a lock-side lower corner of the cover plate construction.

[0041] The attached figures show an embodiment of a door leaf 10 for a fire door with a box-and-cover construction. The door leaf 10 comprises a first metal sheet element 12 and a second metal sheet element 14. The two metal sheet elements 12, 14 are formed from metal sheets by folding. The first metal sheet element 12 forms a box 16; and the second metal sheet element forms a cover 18. Between the box 16 and the cover 18, a door leaf cavity 20 is formed, which is filled with a filling 22.

[0042] In Fig. 1 shows the first door leaf broad side 24 formed by the second metal sheet element 14, ie the cover 18. In the Fig. 2 to 5, the four narrow end faces 26, 28, 30, 32 of the door leaf 10 are shown, whereby in Fig. 2 and Fig. 3 vertically arranged narrow end faces 26, 28 and in the Fig. 4 and Fig. 5 horizontally arranged narrow end faces 30 and 32 are shown.

[0043] For example, the Fig. 2, the narrow end face 26, which is to be arranged vertically, has the lock side 34, which is provided approximately centrally with a lock receptacle 36 in which a door lock 38 with latch (catch) 40 and bolt 42 is accommodated.

[0044] For example, the Fig. 3, the vertically arranged narrow end face 28 is the hinge side 44, which is provided with a first hinge 46 and a second hinge 47 and securing bolts 48. The Fig. 4 shown horizontally arranged narrow end face 30 is the top side 50 and the one in Fig. The horizontally arranged narrow end face 32 shown in Figure 5 is the underside 52, which is provided with a lower door groove 54. The door leaf 10 is rebated on three sides, with a rebate 56 formed by staggering on the cover 18, projecting from the vertically arranged narrow end faces 26, 28 and the upper horizontally arranged narrow end face 30. The box 16 formed by the first sheet metal element 12 forms the second door leaf broad side 58.

[0045] The door leaf 10 is designed to be completely thermally separated, such that the sheet metal elements 12, 14 are only indirectly connected via a thermal insulation material 60 with poor thermal conductivity compared to metal. For this purpose, a narrow gap 62 is provided between the sheet metal elements 12, 14 on the two vertically arranged narrow end faces 26, 28, on the upper horizontally arranged narrow end face 30, and within the door groove 54 on the lower horizontally arranged narrow end face 32, so that the sheet metal elements 12, 14 do not touch each other. The sheet metal elements 12, 14 are indirectly connected to one another via a filling element 64, 65, which is housed in side cavities 66, 68 provided in the area of ​​the narrow end faces 26, 28, 30, 32. These side cavities 66, 68 will be discussed in more detail below.

[0046] In Fig. 6 is the Fig. 3 shows a detail of the connection of the door hinge 47. The door hinge 47 has a door leaf-side hinge frame part, which is attached to the hinge side 44.

[0047] Fig. Figure 7 shows a horizontal section along line VII-VII through the door leaf 10, showing the panel 22 between the sheet metal elements 12, 14. The outermost side regions of the narrow end faces 26, 28, 30 are further thermally insulated by additional strips 152 of thermal insulation material 60.

[0048] Fig. Figure 8 shows a cross-sectional view of the lock receptacle 36 with the door lock 38. The door lock 38 is protected by side panels 150 made of thermal insulation material 60.

[0049] Fig. 9 shows detail IX of Fig. 7 with the first side cavity 66; Fig. 10 shows the section along the line XX through the entire door leaf 10 with filling and upper and lower areas of the narrow end faces 30, 32; and Fig. 11 shows a detail of the upper region of the horizontally arranged narrow end face 30 with the first side cavity 66. The first side cavity 66 is filled with a first filling element 64. Fig. 12 shows the lower region of the narrow end face 32 to be arranged horizontally at the bottom with a second side cavity 68 formed differently from the first side cavity 66. The second side cavity 68 is filled with a second filling element 65.

[0050] The design of the side cavities 66, 68 and the filling elements 64, 65 inserted therein is described below with reference to the illustrations in the Fig. 9, Fig. 11 and Fig. 12 is explained in more detail.

[0051] The first filling element 64, which is Fig. 9 and Fig. 11, comprises a first strip 70 and a second strip 72 made of filler material 74 formed by the thermal insulation material 60, with a reinforcing strip 76 made of a material with a higher mechanical strength than the thermal insulation material 60 being embedded between the two strips 70, 72. For example, the reinforcing strip 76 is formed from sheet metal 78. The strip of sheet metal 78 has a significantly smaller thickness than the two strips 70, 72 and is also provided with a smaller width transversely to the longitudinal extent of the strips 70, 72 than the two strips 70, 72.

[0052] The strips 70, 72 of thermal insulation material 60 protrude on both sides beyond the reinforcing strips 76, so that even when using sheet metal 78 as reinforcing material, no thermal bridge or cold bridge is created between the sheet metal elements 12, 14.

[0053] The edges of the side cavities 66, 68 are preferably formed by folding over side regions of the metal panels forming the sheet metal elements 12, 14.

[0054] In the Fig. 9 and Fig. 11, the edge essentially has a C-profile structure 80 with a C-web 82 and two C-legs 84, wherein at the free ends of the C-legs 84 formed on the narrow end faces 26, 28, 30, C-flanges 86 directed towards one another protrude perpendicularly to the C-legs 84 towards one another and leave the gap 62 free between them.

[0055] As in Fig. As indicated in Figure 11, the gap 62 has a width S that is approximately in the range of the width F of each C-flange 86. For example, the width S of the gap 62 is approximately 1 / 3 (± 10%) of the total width (S+2xF) of the first side cavity 66.

[0056] In a preferred embodiment, the C-profile structure 80, which forms the edge of the first side cavity 66, is formed partly by an edge region 88 of the first sheet metal element 12 and partly by an edge region 90 of the second sheet metal element 14.

[0057] Preferably, each of these edge regions 88, 90 is shaped such that it is formed into a U-profile 96, 98 from its narrow end profile region 92, 94, which forms the respective outer surface of the narrow end face 26, 28, 30 and runs in the thickness direction of the door leaf, inwards towards the door leaf cavity 20.

[0058] The first U-profile 96 of the first metal sheet 12 has an outer U-leg 100, adjoining thereto a first U-web 102 and adjoining thereto an inner U-leg 104, wherein the U-legs 100, 104 and the U-web 102 connecting them form a first U-profile groove 106 which is open towards the second metal sheet element 14.

[0059] The edge region 90 of the second sheet metal element 14 has a correspondingly complementary second U-profile 98 with a second outer U-leg 108, a second U-web 110 and a second inner U-leg 112. The two second U-legs 108, 112 and the second U-web 110 located therebetween together form a second U-profile groove 118 which is open towards the first U-profile groove 106.

[0060] Fig. 13 shows a view from the inside of the door leaf cavity without filling, looking at the C-web 82 of the vertically arranged narrow end faces 26, 28 and Fig. 14 shows a view from the interior of the door leaf cavity without filling upwards onto the C-web 82 on the upper horizontally arranged narrow end face 30. It can be seen that the inner U-legs 104, 112 of the two sheet metal elements 12, 14 have complementary sequences of projections 120a, 120b, 121a, 121b and recesses 122a, 122b, 123a, 123b which engage with one another. The first projections 120a, 120b of the edge region 88 of the first metal sheet element 12 engage in the second recesses 123a, 123b of the edge region 90 of the second metal sheet element 14, while the second projections 121a, 121b formed on the second metal sheet element 14 engage in the first recesses 122a, 122b. It is furthermore the Fig. 13 and Fig. 14 that there is a minimum distance A between the projections 120a, 120b, 121a, 121b and the recesses 122a, 122b, 123a, 123b, so that the edge regions 88, 90 of the sheet metal elements 12, 14 do not touch.

[0061] As in Fig. 13 using the example of the vertically arranged end faces, the projections 120a, 121a and the recesses 122a, 123a can be rectangular. Using the example of the Fig. 14, it is shown that the projections 120b, 121b and the recesses 122b, 123b can also be trapezoidal in shape with oblique transitions, so that the projections 120b, 121b and the recesses 122b, 123b engage behind one another in a form-fitting manner and can hook behind one another when the metal sheets move apart, e.g. in the event of a fire.

[0062] As can be seen from the Fig. 13 and Fig. 14, the inner U-legs 104, 112 engage with each other with projections / recesses and together form the C-web 82. One of the C-legs 84 is formed by the first U-web 102, and the other C-leg 84 is formed by the second U-web 110. The C-flanges 86 are formed by the outer U-legs 100, 108, which are folded back completely on the narrow end profile area 92, 94, so that the C-flanges 86 are reinforced by double folds.

[0063] In Fig. 13 and Fig. 14, fasteners 124, in particular formed by self-tapping screws 126, are indicated, which connect the respective projections 120a, 120b, 121a, 121b to the first filler element 64 and there engage, in particular, into the metal sheet 78 of the reinforcement strip 76. Since the reinforcement strip 76 is surrounded by thermal insulation material 60, it is thermally insulated from the metal sheet elements 12, 14. This results in an indirect fastening of the metal sheet elements 12, 14 solely via the filler material of the filler element 64.

[0064] In the Fig. In the lower narrow end region 32 shown in Figure 12, a second side cavity 68 is formed, which is different from the first side cavity 66 and is filled by a second filling element 65. This second filling element 65 is simply formed from a strip of thermal insulation material 60.

[0065] The door groove 54 is formed by folding the first lower edge region 128 of the first metal sheet element 12 back by 180°, starting from the main region forming the second door leaf broadside 58, to form a double-folded lower profile edge region 130. This is followed by a 90° bend, so that the edge region 128 extends further in the thickness direction and forms the groove base 132 of the door groove 54. This groove base 132 does not extend all the way to the second metal sheet element 14, but ends at a distance from it.

[0066] The second lower edge region 133 of the second metal sheet 14 is initially bent by 90° in the thickness direction, starting from the main region forming the first door leaf broadside 24, to form an outermost lower profile region 134; this is followed by a stepped formation 136 with two stepped flanks 138, 140, whereupon the second lower edge region 133 has an upwardly extending edge end strip 142. The edge end strip 142 is designed to end at a distance from the groove base 132, so that the gap 62 between the metal sheet elements 12, 14 is formed here. As a result, the second lateral cavity 68 is delimited on its upper side by the groove base 132 and is encompassed on its three other sides by the second lower edge region 133 of the second metal sheet element 14. The second lower edge region 133 is fastened to the first lower edge region 128 by a series of fasteners 124, which are designed, for example, as drilling screws 126.Here, a ring 146 made of heat insulation material 60 in the manner of a washer is inserted between a screw head 144 and the second lower edge region 133, for example between the screw head 144 and the step flank 140.

[0067] The Fig. 15 to 19 show a perspective exploded view of the door leaf 10 with the first metal sheet element 12, the second metal sheet element 14 of the filling 22 and the elements of additional thermal insulation material 60.

[0068] The filling 22 is formed, for example, by a mineral fiber board 148, which is bonded to the inside of the metal sheet elements 12, 14 over a large area on the door leaf broad sides 24, 58. The thermal insulation material 60 is preferably strips of a mineral fire protection board, in particular preferably based on vermiculite. For example, the company Knauf offers a corresponding fire protection board under the brand name "Thermax". The strips 70, 72 of the first filling element 64 and the second filling element 65 are cut from such a mineral board. The lock receptacle 36 is also insulated by small board elements 150 made of this thermal insulation material 60. Additional strips 152 made of this thermal insulation material 60 are arranged around the C-profile structures 80, as can be seen in particular from the Fig. 9 and Fig. 11 and 14 and the Fig. 15, Fig. 16 and Fig. 18 and 17.

[0069] The area of ​​the fold 46 is also defined by such additional strips 152, which have a Fig. 15, formed from the heat insulation material 60.

[0070] During the production of the sheet metal elements 12, 14, the U-profiles 96, 98 are formed from sheet metal panels by cold forming the edge areas, starting from the outside inward. Finally, the double folds of the C-flanges 86 are pressed on.

[0071] Overall, a door leaf 10 made of cost-effective materials has been created, which can also meet high fire protection classes and is also particularly thermally insulating. The door leaf 10 can thus also be used as a door between rooms with large temperature differences, for example, as a partition between a living area and a garage or as an exterior door, and contributes to energy savings through the complete thermal separation between the door leaf broad sides 24, 58.

[0072] The formation of the side cavities 66, 68 by profile structures 80, 96, 98 results in a high rigidity of the door leaf 10, which is further reinforced by the reinforcement strip 76 running along the narrow end faces 26, 28, 30. The sandwich structure contributes to additional stiffening by bonding the metal sheet elements 12, 14 to the filling 22.

[0073] In summary, it can be said: The invention relates to a door leaf 10 in box-and-lid construction, in particular a fire-resistant door leaf, with a first and a second metal sheet element 12, 14, each formed from a metal sheet, which together enclose a door leaf cavity 20, and with a filling 22 inserted in the door leaf cavity 20, wherein on at least one narrow end face 26, 28, 30, 32 of the door leaf 10, edge regions 88, 90; 128, 133 of the metal sheet elements 12, 14 have a longitudinally extending edge region 88, 90; 128, 133 of the metal sheet elements 12, 14, which edge region 88, 90; 128, 133 extends in the longitudinal direction of the at least one narrow end face 26, 28, 30, 32 and is guided in a recess 88, 90; 128, 133, which is filled with a filling material 74 which is a poorer thermal conductor than the metal sheet, wherein the edge regions of the metal sheet elements 12, 14 surrounding the side cavity 66, 68 are indirectly connected to one another via the filling material 74, without the metal sheet elements 12, 14 directly touching one another.This enables a completely thermally separated door leaf 10 with particular rigidity to be produced using simple means and little metal material. List of reference symbols: 10 door leaf 12 first metal sheet element 14 second sheet metal element 16 boxes 18 lids 20 door leaf cavity 22 Filling 24 first door leaf broadside 26 vertically arranged narrow front side 28 vertically arranged narrow front side 30 horizontally arranged narrow front side 32 horizontally arranged narrow front side 34 Castle side 36 Lock holder 38 Door lock 40 traps 42 bars 44 band side 46 first door hinge 47 second door hinge 48 locking bolts 50 top 52 bottom 54 Door groove 56 fold 58 second door leaf broadside 60 thermal insulation material 62 gap 64 first filling element 65 second filling element 66 first lateral cavity 68 second side cavity 70 first strip 72 second stripe 74 Filling material 76 reinforcement strips 78 metal sheet 80 C-profile structure 82 C-bridge 84 C-legs 86 C-flanges 88 Edge area of ​​first metal sheet element 90 edge area of ​​second metal sheet element 92 Narrow end profile area first metal sheet 94 Narrow end profile area first metal sheet 96 first U-profile 98 second U-profile 100 first outside U-leg 102 first U-bridge 104 first inner U-leg 106 first U-profile groove 108 second outer U-leg 110 second U-bridge 112 second inner U-leg 118 second U-profile groove 120a first projections (on vertically arranged end faces) 120b first projections (on the top horizontally arranged front side) 121a second projections (on vertically arranged end faces) 121b second projections (on the top horizontally arranged front side) 122a first recesses (on vertically arranged front sides) 122b first recesses (on the top horizontally arranged front side) 123a second recesses (on vertically arranged end faces) 123b second recesses (on the top horizontally arranged front side) 124 fasteners 126 self-drilling screws 128 first lower edge area 130 lower profile edge area 132 groove base 133 second lower edge area 134 lower profile area 136 stage training 138 step flank 140 step flank 142 edge end strips 144 screw head 146 rings 148 mineral fiber board 150 plate element 152 additional stripes 154 frames made of thermal insulation material S gap width F Width C-flange A Minimum distance

Claims

[1] Door leaf (10) in box-and-lid construction, in particular a fire-resistant door leaf, with a first and a second metal sheet element (12, 14), each formed from a metal sheet, which together enclose a door leaf cavity (20), and with a filling (22) inserted into the door leaf cavity (20), wherein on at least one narrow end face (26, 28, 30) of the door leaf (10), edge regions (88, 90) of the metal sheet elements (12, 14) form a side cavity (66) extending in the longitudinal direction of the at least one narrow end face (26, 28, 30), encompassed by the edge regions (88, 90), which is filled with a filling material (74) which is a poorer thermal conductor than the metal sheet, wherein the edge regions (88, 90) surrounding the side cavity (66) of the Sheet metal elements (12, 14) are connected to one another indirectly via the filling material (74) without the sheet metal elements (12, 14) directly touching one another,wherein the side cavity (66) is filled with a filling element (64) comprising a first strip (70) of thermal insulation material (60) and a second strip (72) of thermal insulation material (60) as filling material (74), and additionally a reinforcing strip (76) embedded between the first strip (70) and the second strip (72), wherein the side cavity (66) is entirely enclosed by a C-profile structure (80) formed by the edge regions (88, 90) of the sheet metal elements (12, 14), and wherein additional strips (152) of thermal insulation material (60) are arranged around the C-profile structure (80) between the C-profile structure (80) and the regions of the sheet metal elements (12, 14) forming the door leaf broad sides (24, 58). [2] Door leaf according to claim 1, characterized bythat the reinforcing strip (76) is formed from metal and is formed with a smaller width than the strips (70, 72) of thermal insulation material (60), wherein the strips (70, 72) of thermal insulation material (60) protrude beyond the reinforcing strip (76). [3] Door leaf according to claim 2, characterized by that the strips (70, 72) of thermal insulation material (60) protrude on both sides beyond the reinforcing strip (76). [4] Door leaf according to one of the preceding claims, characterized by in that the edge region (88, 90) of at least one of the sheet metal elements (12, 14) forms a U-profile (96, 98) which adjoins a profile region (92, 94; 86) of the sheet metal element (12, 14) forming part of the narrow end face (26, 28, 30) and extending in a thickness direction of the door leaf (10) inwards towards the door leaf cavity (20). [5] Door leaf according to claim 4, characterized bythat both the edge region (88) of the first metal sheet element (12) and the edge region (90) of the second metal sheet element (14) are formed in a U-profile manner with U-profile grooves (106, 118) open to one another, so that the U-profile grooves (106, 118) together form the side cavity (66). [6] Door leaf according to claim 4 or 5, characterized by that the profile region (92, 94; 86) extending in the thickness direction is formed by a double fold. [7] Door leaf according to one of the preceding claims, characterized by that the edge regions (88, 90) of the sheet metal elements (12, 14) have, as seen in the narrow end longitudinal direction, successions of projections (120a, 120b, 121a, 121b) and recesses (122a, 122b, 123a, 123b) which are complementary to one another, wherein the projections (120a, 120b) of one sheet metal element (12) engage with the recesses (123a, 123b) of the other sheet metal element (14) without contact, in particular at a distance. [8] Door leaf according to claim 7, characterized by that the succession of projections (120a, 120b, 121a, 121b) and recesses (122a, 122b, 123a, 123b) are formed by rectangular or trapezoidal notches on the outermost edge strips of the metal sheets forming the metal sheet elements (12, 14). [9] Door leaf according to claim 7 or claim 8, characterized by that the projections (120a, 120b, 121a, 121b) are each fastened to the filling material (74) by at least one fastener (124). [10] Door leaf according to one of the preceding claims, characterized by that the filling material (74) is formed by strips (70, 72) of mineral-based fire protection material. [11] Door leaf according to one of the preceding claims, characterized by that the at least one end-side side cavity (66) is formed by repeatedly bending the edge regions (88, 90). [12] Door leaf according to one of the preceding claims, characterized by that the at least one narrow-end side cavity (66) filled with the filling material (74) is open to the outside through a gap (62) extending over the narrow end, the width of which gap is smaller than the extension of the side cavity (66) in the thickness direction. [13] Door leaf according to one of the preceding claims, characterized by that the filling (22) is formed by a mineral fiber board (148) and that the filling (22) and the sheet metal elements (12, 14) are bonded to one another over a large area. [14] Door leaf according to one of the preceding claims, characterized by that at least the two narrow end faces (26, 28) to be arranged vertically and one narrow end face (30) to be arranged horizontally at the top are each formed with the side cavity (66) extending longitudinally over the entire narrow end face. [15] Door leaf according to one of the preceding claims, characterized by that on all narrow end faces (26, 28, 30, 32) a side cavity (66, 68) is provided longitudinally over their entire extent, wherein in a first side cavity (66) provided on the narrow end faces (26, 28) to be arranged vertically and the narrow end face (30) to be arranged horizontally at the top, a first filling element (64) with the filling material (74) is overlapped on the outside by the edge regions (88, 90) of both the first and the second sheet metal element (12, 14), while a second side cavity (68) filled with a second filling element (65) on the narrow end face (32) to be arranged horizontally at the bottom is encompassed on the outside only by the edge region (133) of only one of the sheet metal elements (14), wherein between the lower second side cavity (68) and the Main extension plane of the other metal sheet element (12) has a lower downwardly open door groove (54) formed therein.

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