Door leaf with isotropic expansion compensation

Abstract

Door leaf comprising a frame (14) for holding door components (30) and at least one cover element (12) for covering at least one side of the frame (14), wherein the frame (14) is formed from a plurality of profile elements (16) extending in the vertical and horizontal direction, wherein at least one layer of an elastic rheological medium (20) is arranged on at least one profile element (16) to form an elastic connection between the frame (14) and the cover element (12), wherein the elastic rheological medium (20) is designed to allow a thermally induced relative movement of the cover element (12) relative to the frame (14).

Description

Technical field

[0001] The following explanations concern a door leaf that enables the compensation of thermally induced deformations in components made of different materials. Technical background

[0002] It is known that in building formwork, door leaves exposed to different temperatures can deform due to unequal thermal expansion. Conventional systems for connecting frames and facings often use mechanical coupling elements that engage in milled recesses. These designs frequently lead to a weakening of the profile stability and can cause localized stress concentrations. Furthermore, rigid mechanical guides often only allow limited expansion in predetermined preferred directions.

[0003] There is a need to reduce the effects of thermal expansion of door leaves without compromising the static stability of the supporting structure.

[0004] Based on this situation, the task at hand is to propose a door leaf in which the effects of thermal expansion can be reduced and the mechanical strength of the door leaf can be increased. Description - Technical Solution

[0005] The present problem is solved by the features of the independent claim. Advantageous embodiments are specified in the dependent claims, the description, and the drawings. Where technically feasible, the teachings of the dependent claims or descriptive features may be combined arbitrarily with the teachings of the main and dependent claims.

[0006] In particular, the problem is solved by a door leaf comprising a frame for holding door components and at least one cover element for covering at least one side of the frame, wherein the frame is formed from a plurality of profile elements extending in the vertical and horizontal direction, wherein at least one layer of an elastic rheological medium is arranged on at least one profile element to form an elastic connection between the frame and the cover element, wherein the elastic rheological medium is designed to allow a thermally induced relative movement of the cover element relative to the frame.

[0007] The frame forms the structural foundation of the door leaf and securely houses door components such as fittings and locks. The cover element forms the visible outer layer and protects the structure from the elements. The vertical and horizontal profile elements provide the frame with the necessary structural strength. The elastic rheological medium acts as a physical bond, creating a flexible connection that serves as a buffer zone between the rigid frame and the cover element. When the cover element is exposed to significant thermal fluctuations, such as those caused by direct sunlight, it expands or contracts. In this case, the elastic connection allows for relative movement between the two components.This effectively prevents thermal expansion stresses from being transferred to the profile elements, thus counteracting unwanted warping or bending of the overall structure.

[0008] The following sections explain advantageous aspects and subsequently describe preferred modified embodiments. Explanations, particularly regarding advantages and definitions of features, are essentially descriptive and preferred, but not limiting, examples. If an explanation is limiting, this will be explicitly stated.

[0009] Where ordinal numbers, such as "first," "second," etc., are used, for example to designate a component, an element, a process step, or a process action, these ordinal numbers are solely for differentiation in the designation and do not indicate any dependencies or sequences. This means, in particular, that a device does not need to have a "first component" to have a "second component." A device can also have a "first component" and a "third component" without necessarily having a "second component." Multiple units with the same ordinal number are also possible, for example, multiple "first components."

[0010] The term "door components" encompasses all functional parts such as locks, hinges, straps, and internal reinforcements. The term "elastic rheological medium" refers to a medium possessing both elastic and viscous properties to reversibly compensate for mechanical stresses and changes in length, and to absorb shear forces. The term "groove" refers to an elongated, preferably channel-shaped recess in the surface of the profile elements. The term "thermally induced relative movement" describes the kinematic property that the cover element can shift in its own plane as a result of temperature changes, independent of the frame's fixed position. Thus, the cover element is designed to be mechanically decoupled from the frame and, in effect, "floating."The elastic rheological medium absorbs the forces that occur and ensures a permanently dimensionally stable and distortion-free construction, even under extreme one-sided temperature loads.

[0011] Alternatively or additionally, the profile elements may have at least one groove on a side facing the cover element for receiving the elastic rheological medium. In particular, it is provided that at least one layer of an elastic rheological medium is arranged in the at least one groove to form an elastic connection between the frame and the cover element. The targeted incorporation of a groove into the profile elements creates a defined receiving space for the elastic rheological medium.

[0012] Alternatively or additionally, a support element may be arranged at a lower horizontal edge of the frame to form a mechanical stop for the cover element. In particular, the support element is designed to support the cover element vertically and to define a fixed zero line for thermally induced relative movement. Specifically, the support element is fastened to a metal reinforcement of the profile elements by means of fasteners to transmit the weight of the cover element. Specifically, the support element is designed to at least partially overlap an end face of the cover element. Specifically, a seal is provided between the support element and the end face of the cover element. The support element at the lower edge creates a firm and secure bearing.This allows the entire weight of the cover element, which can be made of heavy metal, ceramic, or glass, for example, to be absorbed and transferred into the frame. This prevents the elastic rheological medium from being subjected to continuous vertical shear stress from gravity, which would cause undesirable creep or sagging of the panel. By defining a fixed zero line, thermal expansion is controlled and predictably controlled from this lower fixed point upwards and to the sides. Fastening the cover element to a metal reinforcement ensures a permanently high-load-bearing and statically stable force transmission. This prevents the fasteners from pulling out or the profile elements from deforming under the load of the cover element.The partial overlap of the cover element's front edge creates robust edge protection, safeguarding the cover element from mechanical damage near the floor while simultaneously providing a visually clean finish. The integrated seal between the support element and the front edge effectively prevents the ingress of splash water, moisture, or dirt into the gap between the cover element and the frame. This significantly extends the service life of the elastic rheological medium and the entire door leaf.

[0013] Alternatively or additionally, the thickness of the elastic rheological medium extending from the groove base to the cover element can be functionally dimensioned in relation to the thermal expansion coefficient of the cover element. This ensures that shear deformation remains within the elastic limits of the medium and guarantees continuous adhesion without the transmission of torsional forces to the frame. Functionally dimensioning the layer thickness in relation to the thermal expansion coefficient ensures that the physical properties of the materials used are optimally matched. This allows the elastic rheological medium to provide precisely the space and volume necessary to fully accommodate temperature-induced changes in the length of the cover element.Maintaining shear deformation within the elastic limits prevents the medium from tearing or sustaining structural damage under extreme temperature fluctuations. This ensures a durable and long-lasting bond. Furthermore, continuous adhesion without the transmission of torsional forces effectively prevents the frame from twisting or warping. As a result, the entire door leaf remains absolutely dimensionally stable and fully functional, even under intense, one-sided heat exposure.

[0014] Alternatively or additionally, the elastic rheological medium can be arranged continuously or discontinuously along the frame between the cover element and the frame. A continuous arrangement of the elastic rheological medium ensures a continuous and seamless connection between the frame and the cover element. This allows the acting forces and thermal stresses to be distributed extremely evenly along the entire length of the frame profiles. Furthermore, a continuous arrangement effectively prevents moisture or drafts from penetrating the inner cavity of the door leaf. Conversely, a discontinuous arrangement of the medium allows the elastic rheological medium to be applied section by section and precisely to the statically relevant load zones.This allows for significant material savings in industrial manufacturing. Furthermore, the interrupted arrangement creates targeted ventilation gaps on the back of the cover element, effectively preventing unwanted condensation buildup.

[0015] Alternatively or additionally, the groove bottom can be smooth or textured. In particular, the cover element in the contact area with the elastic rheological medium is designed to have a smooth or textured surface to increase adhesion. A smooth groove bottom or cover element ensures reliable and uniform wetting by the elastic rheological medium. This enables particularly fast and efficient industrial production, as the medium can spread freely. Conversely, a textured surface in the contact area significantly increases the usable contact area for the rheological medium. This results in a strong mechanical interlock between the cover element, the profile, and the elastic rheological medium.This leads to a significant increase in adhesion, reliably preventing unwanted separation of the layers even under extreme thermal and dynamic loads. This improved adhesion ensures the long-term functionality of the elastic connection and thus the dimensional stability of the entire door leaf for many years.

[0016] Alternatively or additionally, the groove may be provided with lateral groove walls, and the elastic rheological medium may be arranged at a distance from these lateral groove walls. In particular, the distance between the lateral groove walls and the elastic rheological medium is intended to form an expansion space for the medium transverse to the longitudinal axis of the groove. Specifically, the groove is intended to have a width of at least 20 mm, preferably at least 25 mm. The lateral distance between the elastic rheological medium and the groove walls ensures that the medium can move freely to the side under mechanical pressure or strong shearing. This effectively prevents the material from being pinched or squeezed laterally between the cover element and the groove bottom during compression.This precisely defined expansion space allows the elastic connection to fully develop its rheological function without premature material fatigue. The specific width of the groove, at least 20 millimeters, or preferably at least 25 millimeters, also provides a sufficiently large volume within the profile. This allows for the application of a correspondingly wide layer of the elastic rheological medium. This is particularly advantageous for reliably accommodating and permanently compensating even extreme temperature-induced displacements of the cover element over long distances. This leads to a significant increase in the reliability of the flexible bearing and preserves the dimensional stability of the entire door leaf structure.

[0017] Alternatively or additionally, at least one seal may be provided between the frame and the cover element. In particular, the seal is provided to be positioned radially downstream of the elastic rheological medium on the frame or the cover element. The arrangement of at least one seal between the frame and the cover element ensures that the inner gap of the door leaf is reliably sealed against external weather influences. This effectively prevents the ingress of rainwater, moisture, or fine dirt into the deeper structure. Furthermore, the radially downstream positioning of the seal optimally protects the elastic rheological medium from direct harmful environmental influences and ultraviolet radiation.This reliably prevents premature material-related aging or undesirable embrittlement of the sensitive medium, thus significantly preserving the long-term elasticity and functionality of the connection. Furthermore, this strategically placed downstream physical barrier creates a hermetically sealed space, thereby significantly improving the thermal and acoustic insulation of the entire door leaf. Alternatively or additionally, the elastic rheological medium can be designed to have an elongation at break of at least 300 percent to allow for stress-free isotropic expansion of the cover element. Such a high elongation at break of at least 300 percent ensures that the elastic rheological medium can react extremely flexibly to mechanical and thermal loads.This allows the medium to easily accommodate and compensate for significant changes in the length of the cover element without structural failure, cracking, or delamination of the bonding layer. Furthermore, by enabling stress-free isotropic expansion, the cover element can expand uniformly and naturally in all directions within its own plane when exposed to strong solar heat. This effectively prevents uneven mechanical stresses from being transferred to the frame structure or the cover element from warping uncontrollably. This ensures long-term dimensional stability and guarantees unrestricted, distortion-free operation of the entire door leaf, even under extreme climatic conditions.

[0018] Alternatively or additionally, the groove can be arranged on an outer wall of the profile elements without penetrating any internal hollow chambers, thus preserving the structural integrity of the profile elements. In particular, the groove is designed as a continuous circumferential groove within the profile elements. By arranging the groove on an outer wall of the profile elements without penetrating any internal hollow chambers, the full structural load-bearing capacity of the frame is maintained. This effectively prevents any mechanical weakening of load-bearing internal structures or insulating chambers of the profile. This results in maximum torsional stiffness and excellent thermal insulation of the entire door leaf, as the physical properties of the multi-chamber profiles remain unaffected.By designing the groove as a continuous circumferential recess in the profile elements, it is also possible for the elastic rheological medium to be applied seamlessly along the entire frame. This ensures an absolutely uniform distribution of the shear forces occurring across the entire circumference of the cover element and simultaneously creates a completely sealed and moisture-resistant gap.

[0019] Alternatively or additionally, the elastic rheological medium can be designed to form a molecular spring capable of absorbing forces in the X, Y, and Z directions of the plane of the cover element. By shaping the elastic rheological medium into a molecular spring, a three-dimensional and highly flexible buffer zone is created between the rigid frame and the cover element. This allows any mechanical and thermal stresses to be completely absorbed without compromising the physical structure of the medium. The targeted absorption of forces in the X and Y directions of the plane effectively prevents the cover element from warping under extreme temperature fluctuations, as changes in length and width across the surface can occur completely unimpeded.Simultaneously, the absorption of forces in the Z direction ensures that wind loads or mechanical impacts acting perpendicularly on the cover element are elastically absorbed and not rigidly transferred into the profile elements. This results in maximum protection of the overall structure and guarantees that the entire door leaf remains free from distortion in all spatial directions.

[0020] Alternatively or additionally, the frame can be made of a material from the group consisting of plastic, metal, wood, and / or composite materials. Choosing these materials for the frame allows the door leaf to be flexibly adapted to a wide variety of static and building physics requirements. This enables an optimal material selection with regard to thermal insulation, weight, or mechanical strength, depending on the application of the door leaf. This results in the invention being universally applicable across different price segments and architectural styles, without compromising the thermal decoupling provided by the rheological medium.

[0021] Alternatively or additionally, the cover element can be made of a material from the group comprising metal, ceramic, glass, laminate, and / or composite materials. Using these materials for the cover element allows for an extremely durable and visually appealing outer surface of the door leaf. Since these solid materials often exhibit significant thermal expansion when exposed to direct sunlight, the interaction with the elastic rheological medium effectively prevents warping of the outer panel. This ensures a consistently attractive appearance and reliable weather protection for the entire structure for many years.

[0022] Alternatively or additionally, the cover element can be designed to completely conceal the frame on the corresponding side of the door leaf, creating a flush appearance. This complete coverage of the frame results in a modern, flush look for the entire door leaf. This eliminates any disruptive edges or visible profile transitions on the visible side of the construction. This not only creates a high-quality architectural aesthetic but also provides full protection for the underlying frame profiles against harmful ultraviolet radiation and direct weathering.

[0023] Alternatively or additionally, the elastic rheological medium can be designed as an MS polymer adhesive or as a double-sided adhesive elastomer tape. In particular, it is provided that a layer of the elastic rheological medium has a thickness of at least 5 millimeters, and preferably at least 8 millimeters, measured between the bottom of the groove and the cover element, to form an elastic expansion cushion and to compensate for radial displacements of the cover element. Designing the elastic rheological medium as an MS polymer adhesive or as an elastomer tape allows the use of materials with outstanding adhesive and viscoelastic properties. This ensures that the elastic connection remains resistant to aging and does not lose its damping effect.The defined thickness of at least 5 millimeters or at least 8 millimeters ensures that a sufficiently dimensioned elastic expansion cushion is formed. This provides the necessary leverage to absorb even extreme radial displacements of the cover element in the groove plane without stress, preventing the adhesive bond from failing or destructive shear forces from being transferred to the groove floor.

[0024] Alternatively or additionally, at least one strip may encompass one end face of the cover element. In particular, a seal is provided between the strip and the cover element. Specifically, the seal is provided on either the strip or the cover element. By encompassing the end face of the cover element with at least one strip, the sensitive edges of the outer panel are mechanically protected. This effectively prevents chipping or damage in the vulnerable edge area in the event of impacts. Furthermore, the seal between the strip and the cover element reliably prevents capillary action by rainwater into the space between the door leaf and the frame. This significantly increases the durability of the internal components.By strategically positioning the seal on the strip or cover element, simple industrial assembly and a permanently tight seal can be achieved. Brief description of the drawings

[0025] A preferred technical solution is explained in more detail below with reference to the accompanying drawings and preferred embodiments. The term "figure" is abbreviated as "Fig." in the drawings.

[0026] The drawings show Fig. 1 A schematic cross-sectional view of an embodiment of a door leaf in a pre-assembled state without a cover element attached; and Fig. 2 the door leaf according to Fig. 1 in an assembled state with the cover element attached. Detailed description of the drawings

[0027] The described embodiments are merely examples that can be modified and / or supplemented in various ways within the scope of the claims. Each feature described for a particular embodiment can be used independently or in combination with other features in any other embodiment. Each feature described for an embodiment of a particular claim category can also be used accordingly in an embodiment of a different claim category.

[0028] Fig. Figure 1 shows a schematic cross-sectional view of a door leaf 10 according to the invention in a pre-assembled state. The door leaf 10 has a frame 14, which is formed from a profile element 16. The frame 14 serves, among other things, to hold door components, which are shown in the upper part of the illustration. A cover element 12 is not yet attached in this illustration but is required for later completion on the left side of the illustration. The profile element 16 has a groove 18 on this left side. A layer of an elastic rheological medium 20 is arranged in the groove 18. The elastic rheological medium 20 is positioned directly on a groove base 22 of the groove 18. The groove 18 has lateral groove walls 24, wherein the elastic rheological medium 20 is arranged at a clear distance from the lateral groove walls 24.This gap between the lateral groove walls 24 and the elastic rheological medium 20 forms an expansion space for the medium transverse to the longitudinal axis of the groove 18. Furthermore, the profile element 16 has a plurality of internal hollow chambers 26. The groove 18 is arranged on an outer wall of the profile element 16 without penetrating the internal hollow chambers 26, thus fully preserving the static integrity of the profile element 16. At least one seal 28 is also arranged on the profile element 16, which is intended for the subsequent attachment of the cover element 12.

[0029] Fig.Figure 2 shows the door leaf 10 according to the invention in an assembled state. The cover element 12 is now arranged on the left side of the frame 14 and completely covers the profile element 16 to create a flush appearance. The elastic rheological medium 20 now forms a direct elastic connection between the frame 14 and the cover element 12. This connection is designed to allow thermally induced relative movement of the cover element 12 with respect to the frame 14, with the previously described expansion space in the groove 18 accommodating the shear deformation of the elastic rheological medium 20. A support element 32 is also arranged at a lower horizontal edge of the frame 14 to form a mechanical stop for the cover element 12. The support element 32 serves to support the cover element 12 in the vertical direction and to define a fixed zero line for the thermally induced relative movement.The seal 28 is arranged radially downstream of the elastic rheological medium 20 between the frame 14 and the cover element 12 and hermetically seals the inner gap. Reference symbol list 10 door leaves 12 Cover element 14 frames 16 profile element 18 Nut 20 elastic rheological medium 22 Grooved floor 24 side groove walls 26 inner hollow chambers 28 Seal 30 support element

Claims

Door leaf comprising a frame (14) for holding door components (30) and at least one cover element (12) for covering at least one side of the frame (14), wherein the frame (14) is formed from a plurality of profile elements (16) extending in the vertical and horizontal direction, wherein at least one layer of an elastic rheological medium (20) is arranged on at least one profile element (16) to form an elastic connection between the frame (14) and the cover element (12), wherein the elastic rheological medium (20) is designed to allow a thermally induced relative movement of the cover element (12) relative to the frame (14). Door leaf according to claim 1, wherein the profile elements (16) have at least one groove (18) on a side facing the cover element (12) for receiving the elastic rheological medium (20), wherein in particular at least one layer of an elastic rheological medium (20) is arranged in the at least one groove (18) to form an elastic connection between the frame (14) and the cover element (12). Door leaf according to claim 1 or 2, wherein a support element (32) is arranged on a lower horizontal edge of the frame (14) to form a mechanical stop for the cover element (12), wherein in particular the support element (32) is designed to support the cover element (12) in a vertical direction and to define a fixed zero line for the thermally induced relative movement, wherein in particular the support element (32) is fastened by means of fasteners in a metal reinforcement of the profile elements (16) to transmit the weight force of the cover element (12), wherein in particular the support element (32) overlaps at least partially an end face of the cover element (12), wherein in particular a seal (28) is arranged between the support element (32) and the end face of the cover element (12). Door leaf according to one of the preceding claims, wherein the layer thickness of the elastic rheological medium (20) extending from the groove base (22) to the cover element (12) is functionally dimensioned in relation to the thermal expansion coefficient of the cover element (12) such that the shear deformation remains within the elastic limits of the medium (20) and ensures continuous adhesion without transmission of torsional forces to the frame (14). Door leaf according to one of the preceding claims, wherein the elastic rheological medium (20) is arranged continuously or discontinuously along the frame (14) between the cover element (12) and the frame (14). Door leaf according to one of the preceding claims, wherein the groove base (22) is smooth or structured, wherein in particular the cover element (12) in the contact area with the elastic rheological medium (20) has a smooth or structured surface to increase adhesion. Door leaf according to one of the preceding claims, wherein the groove (18) has lateral groove walls (24) and the elastic rheological medium (20) is arranged spaced apart from the lateral groove walls (24), wherein in particular the distance between the lateral groove walls (24) and the elastic rheological medium (20) forms an expansion space for the medium (20) transverse to the longitudinal axis of the groove (18), wherein in particular the groove (18) has a width of at least 20 mm, preferably at least 25 mm. Door leaf according to one of the preceding claims, wherein at least one seal (28) is arranged between the frame (14) and the cover element (12), wherein in particular the seal (28) is arranged radially downstream of the elastic rheological medium (20) on the frame (14) or on the cover element (12). Door leaf according to one of the preceding claims, wherein the elastic rheological medium (20) has an elongation at break of at least 300% to enable stress-free isotropic expansion of the cover element (12). Door leaf according to one of the preceding claims, wherein the groove (18) is arranged on an outer wall of the profile elements (16) without penetrating inner hollow chambers (26) to maintain the static integrity of the profile elements (16), wherein in particular the groove (18) is designed as a continuously circumferential groove (18) in the profile elements (16). Door leaf according to one of the preceding claims, wherein the elastic rheological medium (20) is configured to form a molecular spring for absorbing forces in the X, Y and Z directions of the plane of the cover element (12). Door leaf according to one of the preceding claims, wherein the frame (14) is formed from a material from the group comprising plastic, metal, wood and / or composite material. Door leaf according to one of the preceding claims, wherein the cover element (12) is formed from a material from the group comprising metal, ceramic, glass, laminate and / or composite material. Door leaf according to one of the preceding claims, wherein the cover element (12) completely covers the frame (14) on the corresponding side of the door leaf (10) to form a flush appearance. Door leaf according to one of the preceding claims, wherein the elastic rheological medium (20) is designed as an MS polymer adhesive or as a double-sided adhesive elastomer tape, wherein in particular a layer of the elastic rheological medium (20) has a thickness of at least 5 mm, in particular at least 8 mm, measured between a groove bottom (22) of the groove (18) and the cover element (12) to form an elastic expansion cushion and to compensate for radial displacements of the cover element (12). Door leaf according to one of the preceding claims, wherein at least one strip comprises an end face of the cover element (12), wherein in particular a seal (28) is arranged between the strip and the cover element (12), wherein in particular the seal (28) is arranged on the strip or the cover element (12).

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