A fire-resistant and acoustically insulated door panel and a door containing a door panel

Abstract

The present invention relates to a door panel comprising a stile (1) filled with rock wool and covered on both sides with mineral sodium silicate barrier or gypsum board, a door panel comprising MDF board (2) covered on both sides of the mineral sodium silicate barrier or gypsum board barrier, and a door comprising said door panel. The inventive door panel and door provide both fire resistance and acoustic insulation.

Description

[0001] A FIRE-RESISTANT AND ACOUSTICALLY INSULATED DOOR PANEL AND A DOOR CONTAINING A DOOR PANEL

[0002] The present invention relates generally to door panels and doors as one of the building elements and more specifically to door panels that provide both fire resistance and acoustic insulation.

[0003] In the field of building materials, door panels play an important role in the overall safety and comfort of a building's occupants. The design and composition of door panels greatly influence their performance in terms of fire resistance and acoustic insulation.

[0004] Fire resistance is an important parameter, especially in the construction of buildings providing accommodation, such as hotels, dormitories, hospitals, care homes for the elderly or disabled, barracks, refugee housing and residential buildings with more than two storeys. Fire regulations in many modem countries require the use of fire-resistant doors to control or delay the spread of fire and smoke. The fire resistance of a set of doors can be determined by testing against fire and smoke in an accredited laboratory according to test standards EN 1634-1 and EN 1364-3.

[0005] Acoustic comfort or sound insulation is another important consideration in modem buildings. The acoustic performance of a door is measured in decibels (dB) according to the ISO 10140- 2 standard. Sound insulation is particularly important in environments where noise reduction is desirable, for example in residential buildings, offices or educational institutions.

[0006] The materials used in the construction of door panels greatly influence their fire resistance and acoustic insulation properties. Common materials used in the manufacture of door stile in door panels include wood, timber, solid wood and chipboard. Other materials, such as rock wool and mineral sodium silicate or drywall, are used to enhance the fire resistance and acoustic insulation of door panels. Rock wool is a type of mineral wool often used for thermal insulation in buildings and technical applications due to its excellent insulating properties. Mineral sodium silicate and gypsum board is a type of inorganic compound often used as a fire retardant in construction materials.

[0007] Despite the availability of various materials and construction techniques, achieving a balance between fire resistance and acoustic insulation in door panels is a complex task. Increasing the thickness of the layers in the door panel does not increase the fire resistance time and acoustic performance together and in direct proportion. Designing and manufacturing door panels that provide both high fire resistance and acoustic insulation is therefore a nuanced process that requires careful consideration of the materials used and their arrangement within the panel. Many experiments are required to achieve optimum levels of both performances, while at the same time not increasing the thickness of the door panel, complicating the manufacturing process. Other performance criteria include ensuring the mechanical strength of the door panel, its suitability for decorative processing and its suitability for mass production. It is not an easy process to achieve strong effects in terms of both acoustic and fire resistance by changing the thickness of the materials known to be used in acoustically insulated fire doors and the way they are brought together.

[0008] Although fire and smoke doors with 30 / 60 / 90 and 120 minutes resistance are available on the market, they typically have a sound insulation of 32-36 dB. A higher level of sound insulation often requires manual production for fragile, heavy and thick door constructions. This is undesirable and distorts the generally accepted production criteria and general behaviour in the market. In production processes, it is important to combine standard door thicknesses with the desired fire resistance and acoustic performance.

[0009] However, in door panels in the state of the art, door panels with both acoustic insulation of 42dB or more and fire resistance performance of 60 minutes or more are not included in doors of optimum thickness. In order to increase both fire resistance and acoustic performance, it may be necessary to increase the door panel thickness too much and this is undesirable. At the same time, there are cases where the desired level of fire resistance and acoustic insulation cannot be achieved together even if the door panel thickness is increased too much. Therefore, there is a need for a panel such as the door panel of the invention and a door comprising said panel.

[0010] The door panel subject to the invention is an intermediate product and an intermediate product that is suitable for processing and can be transformed into a final product according to the desired specifications.

[0011] The door comprising the door panel according to the invention has a frame in which the door panel is mounted.

[0012] In the acoustically insulated fire doors in the known state of the art, the acoustic performance of doors with 30 minutes fire resistance is generally 30-32 dB. The door panel of doors with 60 minutes fire resistance is generally 54 mm thick and the acoustic insulation performance at this thickness is 34 dB. Doors with 90 minutes fire resistance performance have an acoustic insulation performance of 36 dB. However, when a fire resistance of more than 90 minutes is desired, the acoustic insulation does not increase at the same rate as the thickness of the panel increases. The results of experimental studies on this subject are given in the table below. As can be seen from here, in some tests, there are cases where the acoustic effect decreases although the thickness of the door, that is, the amount of mass through which the sound passes, increases. For example, a panel with a thickness of 88 mm formed with acoustic barriers and similar products has a value of 36.4 dB, while a panel with a thickness of 56 mm, which offers a more positive acoustic effect thanks to the inventive door panel, provides 42.8 dB acoustic insulation.

[0013] Chinese utility model document CN219011549U in the known state of the art discloses a composite rock wool board having thermal insulation, fire resistance and flame retardancy properties. The board consists of decorative panels, a rock wool board, mountable clamping pits and a bone frame.

[0014] Chinese patent document CN105332622A in the known state of the art describes a fireproof and sound-insulating solid wood door plate. The door plate comprises a solid wood door plate body with a fireproof layer on the surface of the door plate and a sound insulation layer above it. The door plate body is treated with environmentally friendly flame retardants. The fireproof layer consists of a glass wool board and a decorative fireproof paint layer from the inside out. The glass wool is coated with unsaturated resin flame retardants and the paint layer contains PVC flame retardants. The sound insulation layer is made of sound insulation felt. The glass wool board is 4.5-6 mm thick, and the paint layer is 2.5-5 mm thick.

[0015] Another Chinese patent document CN105370174A in the known state of the art discloses a sound-insulated fire door. The door leaf consists of fire-resistant glass and a fire-resistant sound-insulating board. Fire-resistant material and sound insulation material are filled between the first and second support frames. At the junction of the door leaf and the door frame there is a fire expansion and sealing strip.

[0016] Another Chinese utility model document CN205778334U in the known state of the art discloses a wooden sound-insulating fireproof door. The utility model aims to improve existing doors with good insulation, durability and ease of use. The door panel according to the invention comprises a stile made of a material selected from a group of materials such as wood, timber, solid wood, chipboard. The stile comprises two horizontal rails and two vertical traverses forming a quadrangular frame in the door panel. It also comprises a door handle stile for mounting the door handle. In the inventive door panel, the stile is filled with rock wool and covered on both sides with a mineral sodium silicate barrier or dry wall. Medium Density Fiberboard (MDF) covers the mineral sodium silicate barrier or gypsum board on both sides of the frame. The inventive door panel provides both fire resistance and acoustic insulation.

[0017] The inventive door panel contains two different products. In the first of these, after the stile is filled with rock wool, the stile and rock wool are coated with mineral sodium silicate and MDF plate is covered on the mineral sodium silicate.

[0018] In another product in the inventive door panel, gypsum board is used instead of mineral sodium silicate to provide fire resistance.

[0019] The acoustic insulation data for the two products in question are shown in bold in the table below.

[0020] In the basic embodiment of the door panel according to the invention, rock wool is covered with a mineral sodium silicate barrier or gypsum board, which at least partially fills the stile.

[0021] The inventive door panel provides a fire resistance of at least 60 minutes and an acoustic insulation of at least 42 dB. The door panel may comprise slats disposed on all four sides of the door panel and fins disposed on slats, whereby a door is formed.

[0022] Thanks to the invention, a door panel and door with an optimum thickness and within the standards for production processes, both acoustic performance and fire resistance performance have been realized. Table 1: Door Panels Tested to Provide Acoustic Insulation and Fire Resistance Performance

[0023] Together and Results

[0024]

[0025] An exemplary embodiment of the invention is illustrated in figures, and from these figures;

[0026] Figure 1- A top view showing the layers of a door panel with fire resistance and acoustic insulation. Figure 2- A sectional view showing the layers of the inventive door panel.

[0027] The references in the figures are shown below:

[0028] 1. Stile

[0029] 2. MDF Plate

[0030] 3. Fire resistant layer

[0031] 4. Acoustic insulation layer

[0032] The door panel which is subjected to invention comprising:

[0033] A door stile (1) made of any material such as wood, timber and solid wood, An acoustic insulation layer (4) containing rock wool, at least partially filling the stile (1),

[0034] A fire-resistant layer (3) coated on both sides of the stile (1) to cover the acoustic insulation layer (4) and MDF board (2) coated on top of the fire-resistant layer (3), Acoustic insulation layer (4) containing rock wool as much as the void formed in 20 to 50 mm thick stile (1),

[0035] A fire-resistant layer (3) comprising a mineral sodium silicate barrier selected from 4 mm to 12 mm in thickness or a layer of gypsum board with a thickness of at least 8 mm and

[0036] - MDF plate (2) with thickness selected from 4 to 12 mm.

[0037] Thanks to the thickness values of the layers used in the inventive door panel, the mineral sodium silicate barrier used for fire insulation and its dimensions, and the dimensions used with gypsum board, door panels with a thickness at reasonable levels for manufacturability and with a fire resistance of at least 60 minutes and acoustic insulation of at least 42 dB are obtained. The performance values of the door panel in question are marked in bold in table 1.

[0038] In one embodiment of the inventive door panel, the door panel comprises an acoustic insulation layer (4) comprising 24 mm thick rock wool filled in a 44 mm thick stile (1), a fire insulation layer (3) comprising 4 mm thick two mineral sodium silicate barriers covering both sides of the stile (1), and two 6 mm thick MDF plates (2) covering the fire insulation layer (3). The product in this application is shown in the table as KYC4A (with door sill). As can be seen from the performance value in the table, the 64 mm thick door panel shows an acoustic insulation performance of 46.4 dB. In another embodiment, the door panel according to the invention comprises an acoustic insulation layer (4) comprising 24 mm thick rock wool filled in a 44 mm thick stile (1), a fire insulation layer (3) comprising two 12.5 mm thick gypsum sheets covering both sides of the stile (1) and two 6 mm thick MDF plates (2) covering the fire insulation layer (3).

[0039] The product in this application is the product named GKC-1 without door sill. As can be seen from the performance value in the table, the 56 mm thick door panel shows an acoustic insulation performance of 42.8 dB. Experiments have shown that gypsum board contributes to both fire resistance and acoustic insulation performance.

[0040] In one embodiment of the invention, the door panel comprises an acoustic insulation layer (4) comprising a rock wool with a density of 20 to 50 kg / m3. This ensures optimum acoustic insulation performance.

[0041] In one embodiment of the invention, the door panel comprises MDF board (2) having a density of 700 to 800 g / m3.

[0042] In one embodiment of the invention, the door panel comprises a stile (1) having a bending resistance of 8.5 N / mm2and an internal bond of 0.2 N / mm2. In this way, the door panel has a durable structure.

Claims

CLAIMS1. A door panel that provides both fire resistance and acoustic insulation comprising:A door stile (1) made of any material such as wood, timber and solid wood, An acoustic insulation layer (4) containing rock wool, at least partially filling the stile (1);A fire-resistant layer (3) coated on both sides of the door stile (1) to cover the acoustic insulation layer (4) and a MDF board (2) coated on the fire-resistant layer (3) wherein:The acoustic insulation layer (4) containing rock wool as much as the void formed in 20 to 50 mm thick stile (1), the fire-resistant layer (3) comprising a mineral sodium silicate barrier selected from 4 mm to 12 mm in thickness or a layer of gypsum board with a thickness of at least 8 mm and the MDF plate (2) with thickness selected from 4 to 12 mm.

2. A door panel according to claim 1, wherein the door panel comprises the acoustic insulation layer (4) comprising 24 mm thick rock wool filled in a 44 mm thick stile (1), the fire insulation layer (3) comprising 4 mm thick two mineral sodium silicate barriers covering both sides of the stile (1), and two 6 mm thick MDF plates (2) covering the fire insulation layer (3).

3. A door panel according to claim 1, wherein the door panel comprises the acoustic insulation layer (4) comprising 24 mm thick rock wool filled in a 44 mm thick stile (1), the fire insulation layer (3) comprising two 12.5 mm thick gypsum sheets covering both sides of the stile (1) and two 6 mm thick MDF plates (2) covering the fire insulation layer (3).

4. A door panel according to any of claims 1 to 3, wherein the door panel comprises the acoustic insulation layer (4) comprising a rock wool with a density of 20 to 50 kg / m3.

5. A door panel according to any of claims 1 to 4, wherein the door panel comprises MDF board (2) having a density of 700 to 800 g / m3.

6. A door comprising the door panel according to any of claims 1 to 5.

Images