Fire-resistant core (panel) with heat-insulating and sound-absorbing filling

Abstract

Fire-resistant door core or building panel, comprising a cladding and an inner heat-insulating and sound-absorbing filling, characterized in that the filling has at least one layer of a non-combustible porous ceramic material having a mean pore size of 10-50 µm, a thermal conductivity coefficient of no more than 0.14 W / (m·K) and containing in its chemical composition compounds which produce several endothermic effects in the temperature range of 110-800°C, which in total increases the fire resistance duration of the construction to at least 120 minutes (EI 120) with a core thickness of no more than 64 mm and, thanks to the fine-pored structure, ensures a sound absorption coefficient of the filling material of at least 0.6 in the frequency range 500-2000 Hz.

Description

[0001] TECHNICAL FIELD: The invention relates to the construction industry, in particular to the construction of fire doors, walls, and cladding panels. It can be used to reduce the weight of fire doors and gates, to increase fire resistance, and to provide thermal and acoustic insulation for rooms.

[0002] STATE OF THE ART: Fire doors with a gypsum board frame and mineral wool insulation are known. Disadvantages of such constructions include their high weight, the release of phenol-formaldehyde or other harmful organic compounds in the event of a fire, and the tendency of fibrous materials to compact and lose their insulating properties over time.

[0003] Most analogues, e.g. patents CN 113216670 A, RU 2793558 C1, RU 2750480 C1, do not meet the entire set of properties required by the customer.

[0004] The next closest state-of-the-art document is patent US 2020 / 0370454 A1, which describes a complex of solutions for achieving several endothermic effects, but does not contain any information on sound absorption (sound insulation) and biopersistence.

[0005] Solutions are known that aim either at increasing fire resistance or sound insulation. Combined solutions either use complex constructions or materials without sufficient bioresistance, or they do not guarantee the required long fire resistance duration (more than 120 minutes) for core thicknesses up to 64 mm, which could be achieved through a series of time-controlled endothermic reactions in the filling material. These solutions also did not address the goal of reducing the weight of the fire-resistant core. TECHNICAL TASK:

[0006] The object of this invention is to provide a construction of a door / panel core with a predetermined thickness of 64 mm and a reduced surface weight of up to 17.5 kg / m². 2 to create a product that does not have the aforementioned disadvantages and ensures fire resistance (El 120) through the use of a special porous filling, which also gives the product high sound insulation properties and bio-resistance.

[0007] The invention aims to increase the fire resistance duration of the core of a fire door (panel) to 120 minutes and more with a thickness of no more than 64 mm, to ensure stable high thermal and sound insulation properties throughout its entire service life, and to give the construction fundamental bio-resistance. SUBJECT OF INVENTION:

[0008] The problem is solved by constructing a fire-resistant door or panel core comprising a facing (1) and an inner infill (2). The infill (2) includes: two outer layers of fibrous glass-basalt materials as facing (1) and at least one infill layer (2) of a special non-combustible porous ceramic material (4) spatially reinforced with cut carbon-basalt fibers (3).

[0009] The spatial reinforcement with cut carbon-basalt fibers (3) ensures the necessary stiffness and strength of the core despite the low density of the porous material (4), which is similar to ceramic in its chemical composition. This porous material (4) is characterized by: 1. A structure with predominantly closed micropores with a mean size of 10-50 µm, which ensures a thermal conductivity coefficient of no more than 0.14 W / (m·K) and effective absorption of sound waves (sound absorption coefficient of at least 0.6 in the frequency range 500-2000 Hz). 2. The presence of compounds in its chemical composition that cause a series of endothermic reactions (phase transitions with heat absorption) in the temperature range of 110°C to 800°C. This creates a thermostabilizing barrier and slows down the heating of the structure in the event of a fire. 3. In principle, biopersistence (antiseptic properties) due to the alkaline character and ionic composition, which suppresses the growth of mold and fungi.

[0010] The filling (2) can be combined and may additionally contain layers of fibrous material - cut carbon basalt fibers (3) - in an amount of 0.25 to 2.5% of the mass of the foam ceramic filling.

[0011] The sheathing (1) with a thickness of 0.7 to 12 mm comprises interconnected, chaotically arranged discrete basalt or glass fibers (5) with a diameter of 7 to 16 µm, or mineral wool or nonwoven fabric, as well as a basalt or glass fabric (6) with a mesh size of 5 to 12 mm. BRIEF DESCRIPTION OF THE DRAWINGS: Fig. 1 - Overall view of the patent-pending fire-resistant core (panels). Fig. 2 - Cut 1-1 Fig. 3 - Structure of the filling under magnification Fig. 4 - Structure of the planking when enlarged TECHNICAL EFFECT ACHIEVED: • Increase in fire resistance to EI 120 and more through the “thermal buffer” effect of the endothermic reactions in the filling material. • Synergy of insulation properties: The microporous structure guarantees low thermal conductivity and high sound absorption. • Durability and hygiene: The bio-persistence of the material prevents its biological degradation and the formation of mold within the structure, even under changing humidity conditions. • Weight reduction and dimensional stability: Compared to monolithic concrete fillings, the proposed material is lighter and does not undergo compaction like fibrous insulation materials. • Industrial applicability: The invention can be implemented in existing production facilities for fire doors and sandwich panels.

[0012] This technical solution is provided by Fig. until Fig.confirmed, which show the structure and texture of the door core, whereby 1. Sheathing 2 fillings 3 Cut carbon basalt fibers of the filling 4 - Non-combustible porous ceramic material of the filling 5 Bonded glass-basalt fibers of the sheathing 6 Basalt or glass fabric of the sheathing QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] CN 113216670 A

[0003] RU 2793558 C1

[0003] RU 2750480 C1

[0003] US 2020 / 0370454 A1

[0004]

Claims

[1] Fire-resistant door core or building panel comprising a facing and an inner heat-insulating and sound-absorbing filling, characterized by , that the filling has at least one layer of a non-combustible porous ceramic material with a mean pore size of 10-50 µm, a thermal conductivity coefficient of no more than 0.14 W / (m·K) and contains in its chemical composition compounds that produce several endothermic effects in the temperature range of 110-800°C, which in total increases the fire resistance duration of the structure to at least 120 minutes (EI 120) with a core thickness of no more than 64 mm and, thanks to the fine-pored structure, ensures a sound absorption coefficient of the filling material of at least 0.6 in the frequency range 500-2000 Hz. [2] Door core or panel according to claim 1, characterized by that the material of the aforementioned layer exhibits bioresistance against infestation by mold fungi. [3] Door core or panel according to claim 1, characterized by , that the filling consists of a special non-combustible porous ceramic material, which is spatially reinforced with cut carbon basalt fibers and is located on the inside of the planking. [4] Door core or panel according to claim 3, characterized by , that the sheathing material, located on the two outer layers of the core / panel, contains 3 to 10 times the amount of cut fibers by volume compared to the amount of fiber in the filling, ensuring higher surface strength and flexural stiffness of the product. [5] Door core or panel according to claim 1, characterized by that the aforementioned layer of non-combustible porous ceramic material has a dry bulk density of 180-330 kg / m³ 3 and has a compressive strength of at least 2.0 MPa.

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