Fire Barrier Door Leaf Interlocking Contour Design
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Solution Overview
Problem
Existing methods for producing fire barrier door leaves are costly and do not effectively minimize fire load and thermal insulation gaps, which are critical for efficient fire protection and energy efficiency.
Innovation Solution
A method involving a flat forming blank with a predefined broad side contour and a mat-shaped mineral wool filling material, where the mat shape contour complements the broad side contour, allowing for interlocking and a tight connection without additional production steps, reducing costs and enhancing fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to produce fire barrier door leaves, then fire protection function is achieved, but manufacturing cost is high and gaps may exist within the door leaf
Solution Approach 1:
The mat shape contour is introduced into the mat-shaped filling material in advance, before assembly with the forming blank. This preliminary shaping action ensures that the filling material will fit tightly against the broad side contour without requiring additional production steps later, thereby reducing manufacturing cost while maintaining fire protection reliability
Solution Approach 2:
The filling material is given a specific mat shape contour that complements the broad side contour at the interface where contact occurs. This localized shaping ensures tight connection at the critical interface area, preventing gaps that would compromise fire protection, while the rest of the filling material maintains its original form for cost-effectiveness
2Ease of manufacture
If gaps are present within the door leaf, then manufacturing is simpler, but fire gases can escape and fire protection is compromised
Solution Approach 1:
The mat shape contour is pre-introduced into the filling material to ensure proper fit and eliminate gaps before final assembly. This preliminary action prevents the formation of gaps that would allow fire gas escape, while still maintaining manufacturing simplicity by avoiding complex additional production steps
Solution Approach 2:
The contour shaping is applied locally at the interface area where the filling material contacts the forming blank. This localized intervention ensures tight connection precisely where needed to prevent fire gas escape, without requiring the entire filling material to be complexly shaped, thus maintaining manufacturing simplicity
3Reliability
If additional production steps are used to ensure tight connection, then fire protection is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The mat shape contour introduction is merged with the existing forming process. By integrating the contour shaping into the filling material preparation step that already exists in the production workflow, the solution achieves tight connection for fire protection without adding separate, complex production steps
Solution Approach 2:
The contour shaping is performed in advance during the filling material preparation phase, combining multiple functions into one preliminary action. This approach ensures tight connection for fire protection while avoiding the need for additional complex production steps later in the manufacturing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method results in a cost-effective door leaf with improved fire protection and thermal insulation by minimizing gaps and using a compacted mineral wool mat for enhanced stability and fire resistance, achieving a significant reduction in fire load and production costs.
Implementation Method 1
advantages result from the introduction of the mat shape contour into the mat-shaped filling material, for example if the filling material is compacted during this introduction
Data Source
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AI summary
The invention relates to a method for manufacturing a door leaf (10), wherein a flat forming sheet (38) and a mat-shaped filler material (28) are provided, a predefined broad-side contour (14) is embossed into the forming sheet (38) and a predefined mat-shaped contour (36) is embossed into the mat-shaped filler material (28), and then the forming sheet (38) and the mat-shaped filler material (28) are joined together such that the broad-side contour (14) engages the mat-shaped contour (36). The invention further relates to a door leaf (10) that is manufactured, in particular, by such a method.