DE202022101604U1 - Inlay for metal doors - Google Patents

Abstract

Inlay for the production of metal doors, with a sandwich panel which has at least two layers, the layers being connected in sections with an adhesive, characterized in that
- the layers are mineral plates,
- the mineral tiles have a density of 340 kg/m ³ to 420 kg/m ³ , in particular 380 kg/m ³ to 400 kg/m ³ and a thickness of 18.5 mm to 31 mm,
- and between the layers there is a gap with a thickness of 0.4 mm to 2.5 mm, in particular between 0.5 mm and 2 mm.

Description

The invention relates to an inlay for the production of metal doors, with a sandwich panel which has at least two layers, the layers each being connected in sections, and a metal door with such an inlay.

Inlays made of sandwich panels are provided for the production of metal doors that are used as interior doors, apartment entrance doors or exterior doors. In addition to the sandwich panel, the inlays often include framing timbers. The inlays are then appropriately fitted with external metal surfaces and door hardware to complete the metal door.

As with all building materials, the requirements for metal doors are increasing. In particular, the expectations in terms of the soundproofing performance of the doors are constantly being raised, although the doors should not become heavier, stronger or more expensive if possible. In addition, there are often specific fire behavior requirements that the doors must meet.

To achieve the properties, the manufacturers mostly use self-developed sandwich structures, which provide you with selected individual layers of different materials in a specific order. A core problem is that the known sandwich structures for interior doors and apartment entrance doors with the same normal door thicknesses and weights that are usual today hardly achieve sound insulation values in the range of more than 42 dB or only with very complex sandwich structures and expensive materials. In the case of thick doors in the range of 60 mm or more, in particular, these are often extremely heavy in order to achieve the current sound insulation values.

The object of the invention is therefore to provide a light inlay for doors with a thickness of at least approx. 60 mm, with which the increasingly strict requirements in the area of sound insulation and fire protection can be met, in particular sound insulation values of 42 dB measured according to EN ISO 10140-2 can be safely achieved.

The invention solves the problem by an inlay according to claim 1 and a metal door according to claim 9. Advantageous developments of the invention are specified in the dependent claims. All of the features described are fundamentally the subject matter of the invention, either individually or in any combination, regardless of how they are summarized in the claims or how they relate back to them.

The inventive inlay for the production of metal doors comprises a sandwich panel which has at least two layers connected in sections, the layers being mineral panels which have a density of 340 kg/m ³ to 420 kg/m ³ , in particular 380 kg/m ³ to 400 kg/m ³ and a thickness of 18.5 mm to 30 mm and a gap between the layers with a thickness of 0.5 mm to 2 mm is arranged.

The inlay has no further decoupling layers made of paper, foam, etc., for example.

It has been found that mineral panels with a density of 340 to 420 kg/m ³ , in particular 380 to 400 kg/m ³ , produce particularly good soundproofing values (measured according to DIN EN ISO 10140-2) for the inlay and the metal door made from it. Surprisingly, it has also turned out that the sound insulation values tend to deteriorate, especially in the case of mineral panels with a higher density. The density is in a range that keeps the overall weight of the inlay and thus also the later door low. The layers of the inlay are made up of at least largely identical material, so that particularly simple processing is also made possible. In addition to the identical material, the layers are preferably also constructed at least largely identically in terms of their dimensions, as a result of which the high sound insulation values can be achieved in a particularly simple manner. In particular, the inlay does not include any further layers in addition to the mineral plates.

In addition to the surprisingly good sound insulation already mentioned, the mineral panels can also absorb high loads in the area of fire protection, since they already have a high level of fire protection. The mineral panels are particularly advantageously designed as mineral fiber panels, in particular mineral wool panels, which preferably contain a mineral wool and/or a mineral wool mix of rock wool and/or glass wool. In addition to the rock wool and/or glass wool components, the mineral fiber or mineral wool panels comprise a binder, preferably based on renewable raw materials, advantageously a binder based on corn starch and/or wheat starch. The mineral plates have a flexural rigidity that allows the mineral plates to be handled easily by machine and/or by hand in the manufacturing process. Mat-like mineral bodies, which are often known from the field of thermal insulation, for example, but which do not have the flexural rigidity that characterizes these mineral bodies as plates, are not mineral plates within the meaning of the invention.

Regardless of the materials, it has been found that for achieving high In terms of sound insulation values for sandwich panels, decoupling individual layers from one another can be advantageous. This is achieved, for example, by using sound-insulating intermediate layers. Individual layers are also only connected to one another in sections, for example using adhesive dots or clip systems. A generally advantageous arrangement of the adhesive points, which brings about an improvement in the sound reduction index independently of the materials used, has not yet emerged, but the arrangement of the adhesive points or the necessary adhesive surfaces are often dependent on the materials used in the individual layers of the sandwich panel.

In addition to the connection in sections, it is provided according to the invention that a gap, usually an air gap, is formed between the layers, i. that is, there is a gap between mating surfaces of the plies. It was surprisingly found here that in the case of layers of mineral plates, the gap should preferably have a thickness of between 0.4 mm and a maximum of 2.5 mm, in particular between 0.5 and 2 mm, in order to achieve particularly high sound insulation performance.

In a metal door, the inventive inlay achieves a sound insulation value of at least 42 dB measured according to DIN EN ISO 10140-2 and a fire resistance EI 30 measured according to EN 1634-1. The inlay is designed for a metal door. In other words, to complete the door, the inlay is encased with sheet metal, in particular surrounded by two metal shells, so that it is not visible on the subsequent metal door. Due to the high sound insulation values and the low density, the structurally very simple inlay enables the production of strong metal doors with low weight, good sound insulation and very good fire protection.

According to a development of the invention, the sandwich is constructed in at least three layers, with a middle layer and outer layers arranged on opposite sides of the middle layer. The three-layer structure makes it even easier to achieve the high sound insulation values, so that sound insulation values of over 42 db can easily be achieved with the later metal door. The third or possibly further layers of mineral plates are also largely identical in terms of material and structural design to the two layers. In addition, a corresponding gap is also formed between the layers in the case of a three-layer or multi-layer design. Inlays according to the invention with a three-layer structure made of mineral plates are preferred, since these achieve optimum sound insulation values with minimal effort.

The two-layer, in particular the three-layer inlays are preferably intended for metal doors with a thickness of approx. 60 mm. Accordingly, with a two-layer structure, the mineral panels have a preferred thickness of approx. 28 mm to 31 mm, while with a three-layer structure and a target thickness of the inlay of approx. 60 mm, the mineral panels have a thickness of between 18.5 mm and 20 5 mm, in particular 19.3 mm +/- 1.0 mm.

The connection in sections is understood to mean sections at which the layers are connected and in which there is therefore no gap between the respective layers, but there is a distance between the respective surfaces. The connection can be made, for example, by means of clamps or similar mechanical connection means. The layers are particularly preferably glued together with an adhesive arranged in sections. The distance between the respective layers is particularly preferably formed by means of an adhesive which is arranged with a corresponding thickness and creates a gap. Alternatively or additionally, spacers are arranged between the layers to produce the gap. The bonding then takes place, for example, via the spacers, which are each bonded with their opposite sides to the surfaces of the layers that face one another, that is to say, for example, the middle layer and the outer layer. Of course, the gap between the layers is thus present (in the direction parallel to the surface of the layers) at least in the area between the adhesive sections and/or the spacers. The distance between mutually facing or connected surfaces of the layers should be as homogeneous as possible, also in the area of the adhesive and/or the spacers. The layers are thus also largely aligned parallel to one another.

The spacers can be made of different materials, such as cardboard, wood, rubber or the like. According to a development of the invention, it is provided that the spacers comprise the material of the mineral plates and/or perlite, in particular are formed from it. On the one hand, the material of the mineral plates and/or perlite also ensures good fire resistance and low sound transmission. On the other hand, mineral plate residues and/or perlite residues or door sections or inlays with appropriate spacers are particularly easy to recycle, for example.

Water glass adhesive, for example, is used as an adhesive for inlays. In connection with the inventive inlay made of mineral plates, adhesives based on cyanoacrylate, isocyanate and/or polyurethane are particularly preferred, since they enable a particularly secure bonding of the layers with a small use of adhesive.

The adhesive between the layers is arranged in sections. In the area of door manufacture, for example, punctiform bonding is known as sectional bonding. In order to achieve a connection between the layers of the sandwich that is sufficient for transport and handling in further processing, the adhesive is arranged between the layers as uninterrupted linear adhesive strands. The adhesive preferably covers between 50% and 5%, in particular below 40% to 5%, particularly preferably below 30% to 5%, of the surface of the respective areas of the layers to be bonded. The adhesive strands are preferably between 25 mm and 40 mm wide, in particular 30 mm +/- 5 mm.

In the case of the inlays, the adhesive is particularly preferably arranged in the area of the outer edges of the layers and as adhesive strands extending diagonally to the outer edges of the sandwich panel. It has been found that diagonal strips of adhesive aligned at an angle of between 30° and 60°, particularly advantageously at an angle of 45° to the longitudinal side edges, have a particularly positive effect and enable simple production of the inlays.

Furthermore, the object on which the invention is based is achieved by a metal door for use as an interior door, apartment entrance door and/or exterior door with an inlay as described above and two metal shells surrounding the inlay.

With a metal door, the inlay is completely surrounded by metal panels. According to the invention, this is preferably done by two metal shells which together cover the 6 sides of the inlay. The metal shells are usually glued to the inlay. This is done, for example, over the entire surface. Most preferably, however, three strips of adhesive are arranged, which extend in the longitudinal direction of the door. The strips are particularly preferably between 80 mm and 120 mm wide, in particular 100 mm +/- 15 mm, in order to obtain optimal acoustic decoupling of the metal shells from the inlay. Two strips are preferably arranged in the area of the opposite longitudinal side edge and the third strip is arranged at least largely in the middle between the side edge strips. Surprisingly, exactly this arrangement and orientation has turned out to be particularly suitable for achieving the high sound insulation values. The adhesives can be used as adhesives for gluing the layers of the inlay, which keeps production simple.

According to a development of the invention, it is provided that the layers of the inlay are glued in the door by means of adhesive strips arranged diagonally and arranged on a short and a long side edge of the layers. The above-described gluing of the layers of the inlay on both opposite side edges to produce the inlay has the primary purpose of making the inlay easy to handle and easy to transport. The inlay is also usually produced in a slightly larger size than the later door. For door production, the inlay is reduced (cut) again to the final size in the door, at least on a short and a long side edge. Surprisingly, it turned out that adhesive bonds between the layers can be cut off (removed) on a short and a long side edge. This simple one-sided trimming (i.e. short on one side and long on one side) of the inlays keeps the manufacturing process of the inlays and the metal doors simple and sufficient structural strength with easily achievable good sound insulation values is still guaranteed.

Although some aspects have been described in connection with the inlay, it should be understood that these aspects also constitute a description of the claimed door and vice versa.

• 1 schematisch in einem Querschnitt ein Inlay;
• 2 schematisch in einer Ansicht einer Mittellage mit aufgetragenem Klebemittel zum Verbinden mit einer Außenlage.

The invention is explained in more detail below on the basis of several exemplary embodiments. Show it

• 1 an inlay schematically in a cross section;
• 2 schematically in a view of a middle layer with applied adhesive for connecting to an outer layer.

1 shows schematically in a cross section an inlay 1 with three layers 2,3, a middle layer 2 and spaced apart from the middle layer 2 and arranged on opposite sides in each case an outer layer 3. Between the middle layer 2 and the respective outer layer 3 is a gap 4, here a arranged air gap. The middle layer 2 is connected to the outer layers 3 in sections. For this purpose, an adhesive 5 is arranged in sections between the middle layer 2 and the respective outer layer 3 . Spacers 6 are arranged between the middle layer 2 and the respective outer layer 3 in order to form the thickness of the gaps 4 in a particularly precise manner. As a result, the distance (ie also the gap) between the mutually facing surfaces 8 of the middle layer 2 and outer layer 3 is homogeneously strong over the entire surface of the middle layer 2 and outer layers 3. The gaps 4 are therefore precisely 1 mm thick here. The middle layer 2 and the outer layers 3 are made of identical mineral plates, each with a thickness of 19.3 mm +/- 1 mm and a density of 390 kg/m ³ +/-10 kg/m ³ . To achieve the precise thickness, the mineral plates can be ground to size, for example, on one or both sides. The inlay 1 thus has a largely precise thickness of 59.9 mm.

The mineral panels are mineral fiber panels that contain mineral fibers bonded with a binder. The spacers 6 are made of the same material as the layers 2,3 of the inlay 1 in order to improve recyclability, and are distributed as uniformly as possible over the surface of the respective middle layer 3 in order to ensure the most homogeneous possible gap thicknesses. The adhesive 5 is based on water glass cyanoacrylate, isocyanate or polyurethane and ensures secure bonding of the mineral plates.

2 shows a schematic view of one side of a layer 2.3 1 with applied adhesive 5. It is clearly visible that the adhesive 5 is applied in linear strips of adhesive. Strips of adhesive are arranged in the area of the outer edges 7 (long side edges and short side edges) and additionally aligned diagonally to the outer edges 7 . In this case, the diagonal strips of adhesive were also each arranged to extend between two outer edges 7 . The angle of the diagonal strips of adhesive is preferably 45°, but in this case 30° to the long sides and 60° to the short sides.

reference list

1

inlay

2

middle position

3

outer layers

4

gap

5

adhesive

6

spacers

7

outer edges

8th

surfaces

Claims (11)

Inlay for the production of metal doors, with a sandwich panel, which has at least two layers, the layers being connected in sections with an adhesive, characterized in that - the layers are mineral panels, - the mineral panels have a density of 340 kg/m ³ to 420 kg/m ³ , in particular 380 kg/m ³ to 400 kg/m ³ and a thickness of 18.5 mm to 31 mm, and a gap between the layers with a thickness of 0.4 mm to 2.5 mm in particular between 0.5 mm and 2 mm. inlaid after claim 1 , characterized in that the sandwich panel is constructed in at least three layers, with a middle layer and outer layers arranged on opposite sides of the middle layer. Inlay according to one of the preceding claims, characterized in that the layers are glued together with an adhesive arranged in sections. Inlay according to one of the preceding claims, characterized in that the gap between the respective layers is formed by means of an appropriately strong adhesive. Inlay according to one of the preceding claims, characterized in that spacers are arranged between the layers. inlaid after claim 5 , characterized in that the spacers consist of the material of the mineral plates and/or comprise perlite. Inlay according to one of the preceding claims, that the adhesive comprises water glass, polyurethane, cyanoacrylate, isocyanate. Inlay according to one of the preceding claims, characterized in that the adhesive is arranged in the region of the outer edges of the layers and as adhesive strands extending diagonally to the outer edges of the layers. Inlay according to one of the preceding claims, characterized in that the inlay in a metal door has a sound insulation value of at least 42 db dB measured according to EN ISO 10140-2 and/or a fire resistance EI 30 measured according to EN 1634-1. Metal door for use as interior doors, apartment entrance doors and/or exterior doors with an inlay claim 1 until 9 and two metal shells surrounding the inlay. metal door after claim 10 characterized in that the metal shells are bonded to the inlay in sections via strips of adhesive which are aligned in the longitudinal direction of the door and are designed in the form of strips.

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