Door leaf or door blank

Abstract

To provide a door leaf or a door blank (101, 102, 103, 104, 105) thatThe following features are proposed for a material that is characterized by both high airborne sound insulation and very good fire protection properties: - at least one core layer (10, 12), in particular acoustic, - at least one first layer of panel material (50) associated with a surface of the core layer (10, 12), - at least one second layer of panel material (52) associated with the core layer (10, 12) on its surface facing away from the first layer of panel material (50), wherein at least one adhesive area (20) is provided on the mutually facing surfaces of the core layer (10, 12) and / or the layers of panel material (50, 52), in which the mutually facing layers (50; 10, 12; 52) are bonded or glued together, in particular by means of at least one adhesive agent based on PU (polyurethane) or on PVAc (polyvinyl acetate) or based on EPI (emulsion polymer isocyanate) or based on at least one silane-modified polymer (silane).

Description

Technical field

[0001] The present invention relates to the technical field of door leaves or door blanks, in particular for at least one fire door or for at least one smoke control door or for at least one soundproof door or for at least one combination thereof. State of the art

[0002] Door leaves or door blanks often exhibit relatively high sound permeability and inadequate fire protection properties. For example, it has been found that door leaves or door blanks are subject to significant warping in the event of a fire, so that larger formats are often impractical – also for weight reasons; soundproof doors, in particular, have several layers that are loosely placed in a frame and therefore have an increased thickness, for example, more than about sixty millimeters; in the event of a fire, these loose layers can detach and become unsafe. Description of the present invention: Problem, solution, advantages, preferred embodiments of the present invention

[0003] Based on the disadvantages and shortcomings outlined above, and taking into account the prior art described, the present invention aims to provide a door leaf or door blank that is characterized by both very good fire protection properties and high sound insulation.

[0004] This problem is solved by a door leaf or a door blank having the features of claim 1. Advantageous embodiments and expedient further developments of the present invention are characterized in the respective dependent claims.

[0005] According to the invention, the door leaf or door blank is provided with: with at least one core layer, in particular acoustic, with at least one first layer of sheet material assigned to a surface of the core layer, with at least one second layer of sheet material assigned to the core layer on its surface facing away from the first layer of sheet material, wherein at least one adhesive area is provided on the mutually facing surfaces of the core layer and / or the sheet material layers, in which the mutually facing layers are bonded or glued together, in particular by means of at least one adhesive agent based on PU (polyurethane) or on PVAc (polyvinyl acetate) or on EPI (emulsion polymer isocyanate) or on at least one silane-modified polymer (silane), for example without added formaldehyde (= NAF = no added formaldehyde) and / or without added urea-formaldehyde (= NAUF = no added urea-formaldehyde) as a further optional property.

[0006] According to a preferred embodiment of the present invention, the core layer can be at least one core layer, in particular at least one planar extending insulation panel, for example must be designed as at least one fiberboard or as at least one composite board made of fibers and at least one other material.

[0007] Advantageously, the core layer can be designed as an insulating core with a thickness of approximately three millimeters to approximately 45 millimeters.

[0008] In the case of at least one fiberboard or at least one composite board, for example coconut fibers or cellulose fibers, such as those from wallpaper remnants, can be used, which can achieve increased noise protection or sound insulation (generally, noise protection or sound insulation is generated by mass).

[0009] Alternatively or additionally, other materials such as bitumen, rubber, caustic soda, chalk, mineral wool or silicone can be used, optionally reinforced with a second material.

[0010] According to a convenient embodiment of the present invention, two or more core layers can be provided and the core layers can have different densities, for example such that the starting material inside the door leaf or door blank is Up to approximately 45 percent of the acoustic core layer may be low density, and from approximately 55 percent onwards, a high density acoustic core layer may be arranged.

[0011] Advantageously, the core layer or core layers can at least one insulating layer or insulating material layer, for example filled with chalk, and / or at least one noise protection or soundproofing element, in particular at least one noise protection or soundproofing film, assigned, especially directed towards.

[0012] In the case of two or more core layers, the at least one insulating layer and / or the at least one noise protection or soundproofing element, in particular the at least one noise protection or soundproofing foil, for example, they may be arranged between the first core layer and the second core layer and, if necessary, one or more further core layer(s).

[0013] Preferably, in the case of two or more core layers, the adhesive can be applied between the first core layer and the second core layer. based on polyurethane (PU) or be a heat-resistant white or starch glue or formaldehyde-free dispersion glue, in particular based on PU (polyurethane) or based on PVAc (polyvinyl acetate) or based on EPI (emulsion polymer isocyanate) or based on silane-modified polymer (silane) as a binder.

[0014] If the at least one core layer is formed from two or more parts or is constructed from two or more sub-elements, it is advantageous to arrange at least one butt joint within the at least one core layer in the transition area between the parts or sub-elements.

[0015] According to an advantageous embodiment of the present invention, at least one core layer, in particular the area between the core layer and the sheet material layer, for example near the at least one butt joint, can be assigned at least one intumescent coating or at least one intumescent area, in particular at least one intumescent band or at least one intumescent strip, for example based on graphite, on the basis of phosphate or on the basis of silicate, such as sodium silicate.

[0016] In a preferred embodiment, the first and / or second layer of panel material can be at least one chipboard or at least one particle board, at least one particleboard, in particular at least one oriented strand board, at least one oriented strand board layer or at least one oriented structural board layer, at least one medium-density or high-density fiberboard (M[M]D[ensity]F[ibreboard] or H[igh]D[ibreboard]), at least one veneer layer, at least one magnesium oxide layer, at least one magnesium sulfate layer, at least one silicate layer, in particular at least one sodium silicate layer, at least one plywood layer, or at least one combination thereof, for example with a density of more than approximately 450 kg / m³, such as with a density of more than approximately 700 kg / m³ up to approximately < 1,200 kg / m³, must be trained.

[0017] The first layer of sheet material and / or the second layer of sheet material can each have a thickness of approximately nine millimeters to approximately thirty millimeters.

[0018] According to an advantageous embodiment of the present invention, at least one flame retardant can be added to the material of the first sheet material layer and / or the material of the second sheet material layer, in particular the material of the first sheet material layer and / or the material of the second sheet material layer can be impregnated with the at least one flame retardant.

[0019] In a further advantageous embodiment of the present invention, the first layer of the panel material, in particular the surface of the first layer of the panel material facing away from the core layer, and / or the second layer of the panel material, in particular the surface of the second layer of the panel material facing away from the core layer, can be provided with at least one surface finish or coating, in particular with at least one top layer, for example with at least one medium- or high-density fiberboard or M[Medium]D[ensity]F[ibreboard] or H[igh]D[ensity]F[ibreboard], in particular laminated or bonded.

[0020] According to a preferred embodiment of the present invention, the at least one adhesive area can may be continuous 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 may be section by section or partially, in particular point by point.

[0021] Regardless of this or in connection with this, the at least one adhesive area The adhesive or glue joint must be designed, in particular at least in a semi-circular, meandering or serpentine shape or extending in a straight line, and / or arranged diagonally in relation to the outer edges of the door leaf or door blank.

[0022] In the case of two or more adhesive areas, the adhesive areas can, in an advantageous embodiment of the present invention, be arranged offset from one another from position to position, in particular equally spaced apart from one another or irregularly spaced apart from one another.

[0023] According to a preferred embodiment of the present invention, in particular For the purpose of lateral or sideways or three-sided or four-sided or circumferential sealing and / or for the purpose of creating sealing grooves and / or rebate geometries and / or for the purpose of attaching fittings, at least one edge strip or at least one frame or at least one edge banding, in particular at least one edge banding or at least one edge banding, may be arranged, wherein the edge strip or frame or edge banding may be made in particular of wood, such as maple wood, of wood-based material, of plastic, of magnesium oxide, of magnesium sulfate, of metal, of silicate, such as sodium silicate, or as a composite element and / or may be in particular about three millimeters to about 150 millimeters wide, for example about eight millimeters to about sixty millimeters, such as about 25 millimeters.

[0024] By providing this so-called lipping or stiles and rails, i.e., the edge strip or frame or the edging, particularly laterally or sideways or on three or four sides, on the layered or layered structure, a preferably circumferential profile, in particular a wood profile, is formed, which is useful, for example, in further processing of the sheet or blank and thus in manufacturing the door (basically, stiles are the vertical, rails the horizontal wood components that form the structure of doors or also of windows or of cabinet fronts and hold the panels or glass surfaces together).

[0025] Advantageously, the edge strip, frame, or edging can be wider in the area of ​​the acoustic core layer(s) than in the area of ​​the remaining layers.

[0026] To increase fire protection, the edge trim, frame, or edging can be coated with at least one intumescent coating, in particular based on graphite, on carbon, on phosphate or on silicate, for example on sodium silicate, and / or in particular with a length of about 38 millimeters and / or a width of about two millimeters to about four millimeters, be provided with; in particular, such an intumescent coating may also be embedded or integrated within a, preferably two-part, edge strip or frame or edging.

[0027] Such an intumescent coating has the property of expanding under the influence of heat, forming a heat-insulating foam layer that can protect the underlying material from excessive heat. In some cases, the expansion of the fire-resistant compound also seals joints, preventing flames from escaping, toxic combustion gases from escaping, or blocking the supply of oxygen from the outside.

[0028] Such an intumescent coating allows the fire protection to be set to approximately ninety minutes in the case of glazing and to approximately ninety minutes or more in the case of a double-leaf door.

[0029] According to an advantageous embodiment of the present invention, the edge strip or frame or the edge banding can be arranged, in particular attached, for example by gluing, to the layered or layered structure by means of polyvinyl acetate (PVAc) or polyurethane (PU) adhesive, also in the hot melt variant; in particular, PU adhesive is considered to be very flame-retardant.

[0030] However, a surrounding frame can also be connected, in particular exclusively, via a further cover layer that covers the core and frame.

[0031] Finally, the present invention relates to the use of at least one door leaf or door blank, in particular designed in the manner of a sandwich panel or a sandwich board, according to the type described above, for at least one wooden door, in particular for at least one fire door or for at least one smoke control door or for at least one soundproof door or for at least one combination thereof. Brief description of the drawings

[0032] As discussed above, there are various ways to advantageously elaborate and further develop the teaching of the present invention. For this purpose, reference is made, on the one hand, to the claims subordinate to claim 1; on the other hand, further embodiments, features, and advantages of the present invention are described below, among other things, with reference to the Fig. 1A to Fig. 6GThe illustrated examples of implementation are explained in more detail, whereby any dimensioning and / or measurement specifications are to be understood as purely exemplary, in particular not as limiting.

[0033] It shows: Fig. 1A in horizontal cross-sectional view a first embodiment of a door leaf or door blank according to the present invention; Fig. 1B in vertical cross-sectional view the first embodiment made of Fig. 1A ; Fig. 1Cin perspective top view of the first embodiment from Fig. 1A and Fig. 1B Fig. 1 In a partially cutaway perspective view, the first embodiment is shown. Fig. 1A, Fig. 1B and Fig. 1CFig. 2 in a horizontal cross-sectional view shows a second embodiment of a door leaf or door blank according to the present invention; Fig. 3 in a horizontal cross-sectional view shows a third embodiment of a door leaf or door blank according to the present invention; Fig. 4 in a horizontal cross-sectional view shows a fourth embodiment of a door leaf or door blank according to the present invention; Fig. 5A in a horizontal cross-sectional view shows a fifth embodiment of a door leaf or door blank according to the present invention; Fig. 5B in a horizontal cross-sectional view shows the fifth embodiment from Fig. 5A , however without frame or edge banding; Fig. 5Cin vertical cross-sectional view the fifth embodiment from Fig. 5B ; Fig. 5 In perspective top view the fifth embodiment from Fig. 5B and Fig. 5C Fig. 5 A partially cut-off perspective view of the fifth embodiment from Fig. 5B, Fig. 5C and Fig. 5D; Figs. 6A to 6G show various design, installation and / or processing situations of the first embodiment (see Fig. 1A, Fig. 1B, Fig. 1C, Fig. 1D ), namely as an overview under supervision (cf. Fig. 6A ), in cross-section (see Fig. 6B, Fig. 6C ), in horizontal cross-sectional view (see Fig. 6D ), in vertical cross-sectional view (see Fig. 6E ), in cross-sectional view on hinge side (see Fig. 6F ) and in cross-sectional view on the lock side (see Fig. 6G ).

[0034] Identical or similar designs, elements, or features are found in Fig. 1A to Fig. 6G provided with identical reference symbols. Exemplary embodiments, in particular the best way of implementation, of the present invention

[0035] As a door leaf or door blank (= reference mark 101 in Fig. 1A, Fig. 1B, Fig. 1C, Fig. 1D ; Reference numeral 102 in Fig. 2 ; Reference numeral 103 in Fig. 3 ; Reference numeral 104 in Fig. 4 ; Reference numeral 105 in Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5EA sandwich panel or sandwich board is provided, which has several layers or layers as follows: The core layer, especially for acoustic purposes, also known as an insulating core or as insulation core Designated as such, it can have a thickness of approximately ten millimeters to approximately fifteen millimeters, in particular a thickness of approximately eleven millimeters to approximately fourteen millimeters, and ensures good sound insulation of the door: This can be an insulating panel 10 (see first embodiment according to Fig. 1A, Fig. 1B, Fig. 1C, Fig. 1D ) or by two mutually associated insulation panels 10, 12 (= second embodiment according to Fig. 2 ; third embodiment according to Fig. 3 ; fourth embodiment according to Fig. 4 ; fifth embodiment according to Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5E ) act; more than two insulation panels may also be provided.

[0036] The insulation board 10, 12 can, for example, be designed as at least one fiberboard and, in the illustrated embodiments, functions as an insulating core specifically for wooden doors. The insulating core can also comprise a composite of fibers and other sustainable materials, which enables very good sound insulation properties (up to approximately 43 dB, depending on the core layer(s) and the density) in conjunction with excellent fire behavior (class EI30 to approximately EI90, whereby a stable door construction is recommended) and excellent thermal insulation with good thermal conductivity.

[0037] In the case of a fiber or composite panel 10, 12, for example coconut fibers or cellulose fibers, such as those from wallpaper remnants, can be used, which can provide increased noise protection or sound insulation (generally, noise protection or sound insulation is generated by mass).

[0038] Alternatively or additionally, other materials such as bitumen, rubber, caustic soda, chalk, mineral wool or silicone can be used, optionally reinforced with a second material.

[0039] If the insulation core is composed of two or more such insulation core elements or components or parts, for example for size reasons, at least one butt joint 30, 32 (so-called) can be formed between the individual insulation board elements or components or parts. butt joint ) condition.

[0040] For example, in the area of ​​these butt joints 30, 32, at least one intumescent coating or at least one intumescent area 40, 42 (so-called) can be applied. intumescent strip ) arranged. This creates a flexible and intumescent fire protection seal, for example based on graphite, carbon, phosphate, or silicate, for example based on sodium silicate.

[0041] Under the influence of fire, the intumescent material expands. Such expansion forms a microporous layer; this prevents the passage of flames, smoke, or hot gases, which also contributes to the excellent fire behavior of the embodiments of the present invention.

[0042] The intumescent coating 40, 42 has the property of expanding under the influence of heat and thereby forming a heat-insulating foam layer that can protect the underlying material from excessive heat exposure.

[0043] In some cases, the expansion of the fire-resistant compound also achieves a sealing of, for example, joints, thus preventing flames from escaping and toxic fire gases from escaping, or preventing the supply of oxygen from the outside.

[0044] Not least in view of its mechanical properties, surface hardness and dimensional stability, the insulating core can be used as a single-layer panel with the tightest thickness tolerances (see first embodiment according to Fig. 1A, Fig. 1B, Fig. 1C, Fig. 1D ), as a two-layer plate (see second embodiment according to Fig. 2 ; third embodiment according to Fig. 3 ; fourth embodiment according to Fig. 4 ; fifth embodiment according to Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5E ) or as a multi-layered panel with a solid core thickness of only about ten millimeters to about 45 or even fifty millimeters.

[0045] The insulating core is closed on both sides by a layer of panel material 50, 52. The panel material layer 50, 52 can have a thickness of approximately 15 millimeters to approximately 25 millimeters, in particular approximately 16 millimeters to approximately 22 millimeters, and can consist of at least one chipboard or at least one particle board, at least one particleboard, in particular at least one oriented strand board, at least one oriented strand board layer or at least one oriented structural board layer, or at least one medium-density or high-density fiberboard (MDF).H[igh]D[ensity]F[ibreboard]), consisting of at least one veneer layer, at least one magnesium oxide layer, at least one magnesium sulfate layer, at least one silicate layer, in particular at least one sodium silicate layer, at least one plywood layer or at least one combination thereof, for example with a density of more than about 450 kg / m 3< , such as with a density of more than about 700 kg / m 3< up to about 1,200 kg / m 3< .

[0046] The sheet material layer 50, 52 can have special properties, for example in the form of at least one additive: Such an additive can, for example, be implemented in the form of at least one flame retardant, with which the sheet material layer 50, 52 can be provided in order to have improved fire protection properties, i.e. the sheet material layer 50, 52 becomes flame-retardant due to the additive.

[0047] It is also possible that the material of the panel material layer 50, 52 is highly compressed in order to increase the stability and load-bearing capacity of the door leaf or door blank 101 or 102 or 103 or 104 or 105.

[0048] Independently of this or in conjunction with this, the sheet material layer 50, 52 can be provided with at least one surface finish or surface coating 60, 62 (see third embodiment according to Fig. 3 ; fifth embodiment according to Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5E ), to increase the surface quality of the panel material layer 50, 52, for example in the manner of a medium- or high-density fiberboard or M[Medium]D[ensity]F[ibreboard](-panel) or H[igh]D[ensity]F[ibreboard](-panel).

[0049] In particular, on the surface of the sheet material layer 50, 52 facing away from the core layer 10, 12 (see third embodiment according to Fig. 3) at least one medium density fiberboard and / or high density fiberboard top layer 60, 62 (so-called MDF or HDF top layer) is provided, which is laminated or glued onto the board material layer 50, 52.

[0050] A circumferential frame or edge banding 80, in particular edge banding or edge banding, is connected exclusively via this cover layer or layer 60 or 62 to the panel material layer 50 or 52; this means that the cover layer or layer 60 or 62 covers the panel material layer 50 or 52 and the frame 80.

[0051] As a result, the optionally provided with at least one additive, in particular impregnated, sheet material layer 50, 52 can be laminated or covered on its exposed outer surface (= on its surface facing away from the core layer 10, 12) with M[edium]D[ensity]F[ibreboard] and / or with H[igh]D[ensity]F[ibreboard] for the purpose of surface finishing or surface treatment.

[0052] It is therefore also conceivable that the layered or layered structure of the panel material layer 50, 52 is, for example, in the form of a coarser layer or layer which is enclosed on both sides by a finer layer or layer, whereby the material of the finer layer or layer can also be wood fiber-like, not least for optical reasons, for example on a M[Medium]D[ensity]F[ibreboard] basis and / or on a H[igh]D[ensity]F[ibreboard] basis.

[0053] According to the fifth embodiment Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5EIt can be deduced that the top layer or layer 60 or 62 can additionally also be arranged on the surface of the panel material layer 50, 52 facing the core layer 10, 12; according to this fifth embodiment, each panel material layer 50, 52 is therefore finished on both sides with M[Medium]D[ensity]F[ibreboard] and / or with H[igh]D[ensity]F[ibreboard].

[0054] As illustrated by the exemplary presentation in Fig. 4 (= fourth embodiment) can be removed, a multi-layered structure made of different materials is also conceivable: Accordingly, one or more insulation layers 70, in particular made of wood or wood-based material as insulation material, can be inserted between the outer cover plates 50 or 52 (= layers of panel material) and the inner soundproofing layers 10 or 12. In the fourth embodiment according to Fig. 4If this is not the case, however, an insulating layer 70 is provided between the first inner soundproofing layer 10 and the second inner soundproofing layer 12.

[0055] The insulation layer(s) 70 can be glued diagonally or at points together, fixed at points or laid loosely.

[0056] As illustrated by the exemplary presentation in Fig. 2 (= second embodiment) can be removed, at least one, in particular additional, noise protection or sound insulation element 72, for example in the form of at least one noise protection or sound insulation foil, can be assigned to the core layer 10, 12, which is arranged between the first core layer 10 and the second core layer 12.

[0057] As illustrated by the exemplary presentation in Fig. 3(= third embodiment) can be removed, the core layer 10, 12 can also be assigned more than one, in particular additional, noise protection or soundproofing element 72, for example in the form of more than one noise protection or soundproofing foil, which is arranged on the surface of the first core layer 10 facing away from the second core layer 12, as well as on the surface of the second core layer 12 facing away from the first core layer 10.

[0058] As illustrated by the exemplary presentation in Fig. 4 (= fourth embodiment) can be removed, the insulation layer(s) 70 and the noise protection or soundproofing element(s) 72 can also be combined with each other.

[0059] In an exemplary and appropriate manner, for example, at least one layer of insulation (material) filled with chalk 70 can also lead to increased noise protection or sound insulation.

[0060] Basically, the individual layers or layers in the respective adhesive areas 20 are bonded or glued together, in particular by means of at least one adhesive agent based on PU (polyurethane) or on PVAc (polyvinyl acetate) or on EPI (emulsion polymer isocyanate) or on at least one silane-modified polymer (silane), for example without added formaldehyde (= NAF = no added formaldehyde) and / or without added urea-formaldehyde (= NAUF = no added urea-formaldehyde) as a further optional property.

[0061] For the permanent and firm bonding of the individual layers or strata of the door leaf or door blank 101, 102, 103, 104, 105, adhesive areas 20 are provided on the surface of these layers or strata. The arrangement of these adhesive areas 20 is decoupled from layer or strata to layer or strata, so that these adhesive areas 20 bond from layer or strata to layer or strata with a defined offset They are arranged offset from each other to achieve a particularly durable and firm bond between the individual layers or strata.

[0062] As shown in Fig. 1D (= first embodiment) as well as in Fig. 5E (= fifth embodiment) removable, these adhesive areas 20 can be used in particular as so-called glue linesfor example, spaced approximately 300 millimeters apart, i.e., formed as adhesive or glue joints, whereby the offset of the adhesive areas 20 to each other can be formed in a regular manner, i.e., equally spaced apart from each other, or in an irregular manner, i.e., not equally spaced apart from each other.

[0063] In an advantageous embodiment, the adhesive areas 20 can be arranged diagonally on the layer or layer surface, i.e. neither parallel nor perpendicular with respect to the outer edges of the door leaf or door blank 101, 102, 103, 104, 105.

[0064] Regardless of this or in connection with this, it is also conceivable not to form the adhesive areas 20 as straight-line extending adhesive or glue joints, but for example at least partially circular or meandering or serpentine.

[0065] The adhesive areas 20 can be used, as in Fig. 1D (= first embodiment) as well as inFig. 5E (= fifth embodiment) shown, be designed to extend continuously from one outer edge of the door leaf or door blank 101, 102, 103, 104, 105 to another, in particular the opposite, outer edge of the door leaf or door blank 101, 102, 103, 104, 105.

[0066] However, it is also possible in an appropriate manner to apply the adhesive areas 20 only section by section or only partially, for example only at points or at points, in order to save adhesive or glue while still achieving a permanent and firm bond between the individual layers or strata of the door leaf or door blank 101, 102, 103, 104, 105.

[0067] In a particularly advantageous manner, at those locations where such an adhesive area 20 is provided on a layer or layer of the door leaf or door blank 101, 102, 103, 104, 105, no adhesive area is provided on the layer or layer adjacent to or neighboring to this layer or layer, so that in a partially sectioned top view (cf. for example the illustration according to the first embodiment in Fig. 1D or the representation according to the fifth embodiment in Fig. 5E ) a quasi accordion-like offset of the respective adhesive areas 20 results.

[0068] The sound insulation can be significantly improved by the type, and in particular the pattern, of the gluing of the individual layers or strata achieved by means of the respective adhesive areas 20, for example to a putty value of 46 dB for double-leaf doors (since sound behaves logarithmically, in this order of magnitude an increase of about 3 dB means a doubling of the sound power).

[0069] Due to its very high stability in case of fire, the door leaf or door blank 101, 102, 103, 104, 105 is suitable according to Fig. 1A bis Fig. 6G especially as a smoke control door. Overall, the present invention provides a surprisingly simple, normally flammable, large-format fire and smoke control door with minimal surface waviness and excellent stability in the event of a fire.

[0070] The door leaf or door blank 101, 102, 103, 104, 105 according to the present invention serves to provide a wooden door system for use in education, leisure, healthcare, commerce, hotels, media, broadcasting, and residential settings, as well as in all other areas of life with high noise protection requirements. The door system enables maximum comfort and efficient working conditions.

[0071] Possible design, installation and / or processing situations of the door system are shown based on Fig. 6A (= overview), Fig. 6B ( Solid Timber Insert ( = solid wood inlay), Fig. 6C (= vertical and horizontal cross-sectional view, respectively) and Fig. 6D (= cross-sectional view on hinge and lock side) illustrated.

[0072] The door leaf or door blank 101, 102, 103, 104, 105 according to Fig. 1A bis Fig. 6G It is easy to process by milling and / or bending and is suitable as veneer and laminate. The door leaf or door blank 101, 102, 103, 104, 105 according to Fig. 1A bis Fig. 6G They exhibit very high stability and very smooth surfaces with high acoustic damping properties.

[0073] Examples of possible door designs include single- or double-leaf door elements, each as a solid leaf or glazed, with or without a transom and / or glazed side panel, hung in a block frame. Bezugszeichenliste

[0074] 101Door leaf or door blank first embodiment according to Fig. 1A, Fig. 1B, Fig. 1C, Fig. 1D ) 102(cf. door leaf or door blank (cf. second embodiment according to Fig. 2 ) 103Door leaf or door blank (see third embodiment according to Fig. 3 ) 104Door leaf or door blank (see fourth embodiment according to Fig. 4 ) 105Door leaf or door blank (see fifth embodiment according to Fig. 5A , Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5E) 10 Core layer, in particular first core layer 12 Second core layer 20 Adhesive area 30 Butt joint of the, in particular first, core layer 10 32 Butt joint of the second core layer 12 40 Intumescent coating or intumescent area of ​​the, in particular first, core layer 10 42 Intumescent coating or intumescent area of ​​the second core layer 12 50 Panel material layer, in particular first panel material layer 52 Second panel material layer 60 Surface finishing or treatment of the first panel material layer 50 62 Surface finishing or treatment of the second panel material layer 52 70 Insulation layer or insulating material layer 72 Noise protection or soundproofing element, in particular noise protection or soundproofing foil 80 Frame or Edge bandingin particular edge banding or inset 90a Smoke and / or soundproofing cover or seal or insulation or gasket 90b Smoke and / or soundproofing cover or seal or insulation or gasket 92 Intumescent cover or intumescent seal or intumescent insulation or intumescent gasket or intumescent strip, in particular based on graphite or on carbon or on phosphate or on silicate, for example based on sodium silicate 94 Solid wood inlay or solid wood inlay 96 Intumescent multi-component system, in particular for covering or sealing or insulating, for example based on phosphate 98 Threshold cover or threshold seal or threshold insulation or threshold gasket,

Claims

1. Door leaf or door blank (101, 102, 103, 104, 105) - with at least one core layer (10, 12), in particular acoustic, - with at least one first panel material layer (50) associated with a surface of the core layer (10, 12), - with at least one second panel material layer (52) associated with the core layer (10, 12) on its surface facing away from the first panel material layer (50), wherein at least one adhesive area (20) is provided on the mutually facing surfaces of the core layer (10, 12) and / or the panel material layers (50, 52), in which the mutually facing layers (50; 10, 12; 52) are bonded or glued together, in particular by means of at least one adhesive agent based on PU (polyurethane) or on the basis of PVAc (PolyVinylAcetate) or based on EPI (Emulsion Polymer Isocyanate) or based on at least one silane-modified polymer (silane).

2. Door leaf or door blank according to claim 1, wherein the core layer (10, 12), which is designed in particular as an insulating core with a thickness of about ten millimeters to about 45 millimeters, is configured as at least one core layer, in particular as at least one planar insulating panel, for example - as at least one fiberboard, such as made of coconut fibers or cellulose fibers, or - as at least one composite panel made of fibers and / or at least one other material, optionally reinforced with a further material, such as bitumen, rubber, chalk, mineral wool or silicone.

3. Door leaf or door blank according to claim 1 or 2, wherein two or more core layers (10, 12) are provided and the core layers (10, 12) have different densities.

4. Door leaf or door blank according to at least one of claims 1 to 3, wherein at least one insulating layer or insulating layer (70) and / or at least one noise protection or sound insulation element (72), in particular at least one noise protection or sound insulation foil, is assigned to, in particular facing, the core layer (10, 12).

5. Door leaf or door blank according to at least one of claims 1 to 4, wherein two or more core layers (10, 12) are provided and the adhesive between the first core layer (10) and the second core layer (12) is polyurethane (PU) based or a heat-resistant white or starch adhesive or formaldehyde-free dispersion adhesive, in particular based on PU (polyurethane) or PVAc (polyvinyl acetate) or EPI (emulsion polymer isocyanate) or silane-modified polymer (silane) as a binder.

6. 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 sub-elements and at least one butt joint (30, 32) is arranged within the at least one core layer (10, 12) in the transition area between the parts or sub-elements.

7. Door leaf or door blank according to at least one of claims 1 to 6, wherein at least one core layer (10, 12), in particular the area between core layer (10, 12) and panel material layer (50, 52), for example near the at least one butt joint (30, 32), is assigned at least one intumescent coating or at least one intumescent area (40, 42), in particular at least one intumescent band or at least one intumescent strip, for example based on graphite or on a carbon basis or on a phosphate basis or on a silicate basis, such as based on sodium silicate.

8. Door leaf or door blank according to at least one of claims 1 to 7, wherein the first panel material layer (50) and / or the second panel material layer (52) is at least one chipboard or at least one particle board, at least one particleboard, in particular at least one oriented strand board, at least one oriented strand board layer or at least one oriented structural board layer, at least one medium-density or high-density fiberboard (M[M[D[H[I]F[ibreboard] or H[igh]D[ibreboard]), at least one veneer layer, at least one magnesium oxide layer, at least one magnesium sulfate layer, at least one silicate layer, in particular at least one sodium silicate layer, at least one plywood layer or at least one combination thereof, for example with a density of more than about 450 kg / m³ 3 , such as with a density of more than approximately 700 kg / m³ 3up to approximately 1,200 kg / m³ 3 , are trained or is trained.

9. Door leaf or door blank according to at least one of claims 1 to 8, wherein the first sheet material layer (50) and / or the second sheet material layer (52) each have a thickness of about nine millimeters to about thirty millimeters.

10. 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 sheet material layer (50) and / or the material of the second sheet material layer (52), in particular the material of the first sheet material layer (50) and / or the material of the second sheet material layer (52) is impregnated with the at least one flame retardant.

11. Door leaf or door blank according to at least one of claims 1 to 10, wherein the first panel material layer (50), in particular the surface of the first panel material layer (50) facing away from the core layer (10, 12), and / or the second panel material layer (52), in particular the surface of the second panel material layer (52) facing away from the core layer (10, 12), is provided with at least one surface finish or coating (60, 62), in particular with at least one cover layer, for example with at least one medium-density or high-density fiberboard or M[Medium]D[ensity]F[ibreboard] or H[igh]D[ensity]F[ibreboard], in particular laminated or bonded.

12. Door leaf or door blank according to at least one of claims 1 to 11, wherein the at least one adhesive area (20) is formed - continuously from one outer edge of the door leaf or door blank (101, 102, 103, 104, 105) to another, in particular the opposite, outer edge of the door leaf or door blank (101, 102, 103, 104, 105) or - sectionally or partially, in particular pointwise or pointwise.

13. Door leaf or door blank according to at least one of claims 1 to 12, wherein the at least one adhesive area (20) is designed as an adhesive or glue joint, in particular at least semicircular 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 (101, 102, 103, 104, 105).

14. Door leaf or door blank according to at least one of claims 1 to 13, wherein two or more adhesive areas (20) are provided and the adhesive areas (20) are arranged offset from position (50; 10, 12; 52) to position (50; 10, 12; 52), in particular equally spaced apart from each other or irregularly spaced apart from each other.

15. Use of at least one door leaf or door blank (101, 102, 103, 104, 105), in particular designed in the manner of a sandwich panel or a sandwich board, according to at least one of claims 1 to 14 for at least one wooden door, in particular for at least one fire door or for at least one smoke control door or for at least one soundproof door or for at least one combination thereof.

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