Non-combustible Mineral Silicate Door with Metal Profile Frame
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Solution Overview
Problem
Conventional door constructions using chipboard or wood-based materials fail to meet non-combustibility requirements and are susceptible to moisture damage, limiting their use and stability.
Innovation Solution
A composite door structure featuring a core made of mineral siliceous material with a non-combustible decorative layer comprising impregnated cellulose paper and a reinforcing layer, supported by a metal profile frame, which enhances fire resistance and stability while allowing for various decorative options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional chipboard or wood-based materials are used for door cores, then ease of manufacture and cost are improved, but non-combustibility requirements are not met and moisture resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining mineral siliceous material (perlite, vermiculite, or silica aerogel) as the core material with cellulose fiber reinforcement and non-combustible decorative layers. This composite structure achieves non-combustibility (class A1) and moisture resistance while maintaining manufacturability through standardized panel production processes.
2Strength
If solid wood profiles are used for surrounding edges, then structural support is improved, but susceptibility to moisture ingress increases
Solution Approach 1:
The patent changes the material parameter of the surrounding edge profiles from solid wood to aluminum or other non-combustible metals. This substitution eliminates moisture susceptibility while maintaining structural support function, and additionally provides non-combustibility that wood cannot achieve.
3Adaptability or versatility
If conventional decorative layers with high paper content are used, then aesthetic requirements are met, but fire resistance deteriorates
Solution Approach 1:
The decorative layer is constructed as a composite material system combining cellulose paper with cellulose fibers and non-combustible additives. This composite structure maintains aesthetic versatility through printable surfaces while achieving improved fire resistance by reducing combustible paper content and incorporating fire-retardant components.
4Adaptability or versatility
If larger door dimensions are produced, then adaptability to different applications is improved, but sagging and damage during transport and installation increase
Solution Approach 1:
The patent uses composite materials including cellulose fiber reinforcement embedded in the mineral siliceous core and aluminum profiles for surrounding edges. This composite construction provides enhanced structural stability and rigidity, enabling larger door dimensions without sagging while maintaining stability during transport and installation.
Data Source
Figure 1
AI summary
The present invention relates to a door (T) with a door leaf (4) in the form of a composite construction having a core and a cover layer, characterized by the following features: the core consists of a building material panel (9) made of a mineral silicate material, which has two opposing main surfaces, wherein at least one of the main surfaces is provided with an adhered non-combustible decorative layer (11), that the decorative layer (11) comprises at least a reinforcing layer (12), a paper layer (13) and a cover layer (14) applied to the paper layer (13) and is adhered to the building material panels (9) with its surface facing away from the cover layer (14), and that the building material panel (9) with its decorative layer (11) is provided at the circumferential edges and margins with metal profiles (5) forming a closed support frame (R).