DE2901089A1 - Moulded fire door or partition panel core - of magnesia-cement layer contg. cover sheet and embedded spacers - Google Patents

Abstract

Panel contains an MgO-cement material layer provided with a cover sheet(13), and distributed spacers(14), which are moulded into the MgO-cement layer. Spacer depth equals MgO-cement layer thickness and the spacers extend from cover sheet(13) to the opposite surface of the MgO-cement layer. Panel mfr. in a mould comprises distributing the spacers(14) in mould, casting an MgO-cement slurry and introducing a cover sheet(13) on at least one side. The mass between the large surfaces(12, 13) is compressed, to squeeze the slurry between the cover sheet and the opposite side, until the spacers are in intimate contact between the compacted surfaces(12, 13), whereupon the slurry is left to harden. A panel mfg. appts., fitted with a frame for determining panel outlines, is also claimed. The panels are used as core fillings for fire doors, partitions, wall cladding, etc. Flat, fire-proof panels can be formed.

Description

"Panel for fire-retardant doors or the like. And methods and

Apparatus for its manufacture "The invention relates to a panel For fire-retardant doors, partitions, panels or the like., As well as methods and Device for its production.

The panel according to the invention is particularly suitable for manufacture of the core of fireproof doors.

The use of a core made of fire-resistant material, e.g. a mineral material between the top panels of a door is common known. Experiments to investigate fire resistance have been carried out, where the foamed magnesia cement was used to make the fire resistant Manufacture core of doors. However, such moldings have a tendency that they warp in the heat of the fire, so that the fire resistance properties the doors are affected. Considerable difficulties also arise on when one wants to ensure that the door panels stay flat when the panel surface tends to change the shape of the cover sheet or to use the cover sheets, which are usually not sufficiently flat. This is special disadvantageous when the panels are subsequently veneered or coated be subjected. Any existing irregularity or unevenness prevents this an intimate bonding contact of the veneer or laminate to the door or the door core.

Further difficulties in molding can occur when the molded articles made of magnesia cement materials have a special curing or Require solidification before they can be moved or processed further. this leads to difficulties especially if a subsequent processing or an earlier one Transportation are required.

The chemical action that occurs within the cement material, leads to the generation of heat. If the articles, e.g.

the panels are stacked on top of each other, this results in a rapid Rise in temperature. This can eventually lead to evaporation of the material to lead. This evaporation in turn slows down the hardening process of the cement, so that the hardening period is extended.

In addition, the effect of evaporation can cause the Cover sheet stains occur, which a veneer during the veneering process can penetrate, so that the doors can also have these stains on the outside. Finally, a cover sheet such as cardboard or the like can be damaged by moisture will, resulting in a reduction in quality and impairment of the liability of the Magnesia cement can lead to the leaf.

It is the object of the invention to address the disadvantages indicated as far as possible largely to prevent and to create a fire-resistant panel that is essentially completely flat.

Furthermore, a method for the production is to be specified, after which such a panel can be formed in a simple and reliable manner can be finished without a tendency to warp under the action of fire Panel can be determined. In addition, the surface flatness or flatness should be be improved.

This task is achieved with regard to the panel by the features of the claim 1 solved.

An essential aspect of the invention is that a panel is made with a layer of magnesia cement material with a cover sheet, wherein distributed spacers are arranged in the magnesia cement layer, the depth of which is substantially equal to the thickness of the layer of magnesia cement. The spacer elements thus preferably extend from the cover sheet to the opposite one free surface of the magnesia cement layer. By the spacer elements is first the production is significantly simplified. Because the spacers the thickness of the core determine on the one hand and on the other individual, selected and distributed points determine the planes which for a level flat training of the core are decisive. In addition, the spacers form a support for the cover sheet, so that when a compaction pressure is applied, the cover sheet is intimately and can be connected to the cement without further effort, the cover sheet touches the spacer elements at all points 0 Due to the distributed arrangement of the Spacer elements is at the same time greatly reduced the tendency that the panel unit warps under the action of fire and so the fire retardant effect of a Door or the like. Reduced. Surprisingly, it has been found that the spacer elements even if they consist of material that is not protected against fire, the fire retardant Do not impair the effectiveness of the panel.

According to the invention, the procedural object is achieved by the features of claim 19 solved.

It is essential that spacers are distributed in the mold and be embedded in the magnesium-cement slurry, at least on a cover sheet is placed on the mold on one side of the panel.

There are flat compression elements against the cover sheet and the Guided underside of the form, so that the cement slurry is pressed together between the parts until the spacers are in intimate contact between the compaction surface and the opposite Area is located. Then you leave the Harden the mud.

The distributed spacer elements can be made from an integral layer consist of a material that with recesses to form a cellular Structure is preformed. The layer can, for example, be in the form of a honeycomb or in the form of an egg carton be shaped.

The distributed spacers can also be rows of blocks or Include strips of appropriate materials.

The magnesia cement is preferably applied prior to introduction into the mold foamed.

It was found that surprisingly the time it took to accomplish of the initial hardening process required can be significantly reduced, if you control the temperature of the cement material so that it does not have a certain critical value (at which evaporation of the material occurs) increases. The solidification period can also be decreased by even one less applies pronounced cooling during the initial period through which the generated Heat is dissipated, even if the temperature is not below the evaporation point can hold.

According to the method according to the invention, the heat build-up is at least kept under control by cooling during the initial curing period.

Cooling can be done in a number of ways. In particular, should the cooling take place so that the temperature is kept sufficiently low to to prevent evaporation.

The cooling should expediently take place so that the molding material does not exceed one of 950 C.

The cooling can also be carried out in such a way that the time is increased preferably by 20%, which is necessary until the molding material is the highest Temperature value reached.

Cooling can be done in a number of ways, such as by dissipating heat through the mold and / or through separate base and cover plates. The heat can also be taken from the mold or the mold plates by direct discharge to the atmosphere or by a forced discharge. Cold blown air can be used for forced discharge or a coolant such as water can be passed over the mold. One can also apply a coolant to the mold or through channels in the Guide cover plates.

The task of a simple device for carrying out the method to form is achieved by the measures of claim 42. Here is a frame intended to determine the outline of the panel. The device includes a Cooling plate that is placed on or under the framework and is used to support the Dissipate heat from the mold.

The plate is preferably of a width and / or a length, which is larger than the frame so that the panels fit the perimeter of the shape for ease the cooling.

Heat exchanger means can be provided to remove the heat from the Form or the cover and base plates. The heat exchanger equipment may include an arrangement to a forced flow of a cooling gas or a To direct coolant over the plate or the mold. There can also be cooling devices be provided for cooling the mold or plate.

The invention is based on schematic drawings several execution examples explained in more detail.

They show: FIG. 1 a cross section of five assembled panels or panels, each panel being reproduced in its associated form and on the Top of another panel is shown clamped together.

Fig. 2 is an overview of a material with cavities for introduction is preformed into the construction of the panels of FIG.

Fig. 3 is an overview of an alternatively designed material that with recesses for introduction into the construction of the panels, like the one according to Fig. 1, is preformed.

FIG. 4 shows a cross section of a further panel construction according to FIG Invention, wherein the cut is made perpendicular to the panel surface.

5 shows a cross section parallel to the surface of another panel, which is designed according to the invention.

6 shows a cross section parallel to the surface of another panel according to the invention and FIG. 7 is a schematic plan view showing an alternative Shows arrangement for the production of a panel according to the invention.

Reference is now made to Figure 1. Any mold for making one fire-resistant panel comprises a rectangular frame 10 made of wood, Metal or plastic. The frames 10 are preferably substantially the same Depth # corresponding to the thickness of a panel to be made.

The frames can also be dismantled. A rectangular base plate 11 with dimensions larger than the dimensions of the frame lies on a solid Surface. On top of this base plate 11 is a rectangular metal plate 12 with dimensions larger than the dimensions of the frame but smaller than that Dimensions of the base board arranged. On top of the plate 12 is first one of the frames 10 is arranged so that the plate around the sides of the frame substantially Outstanding amounts. The inner sides of the frame and the surface of the metal plate come with a lining or a layer of one to facilitate removal Material, e.g.

a sheet of polyethylene. There is a face sheet in the frame 13 inserted for the panel, for example made of a hardboard or consists of a chipboard. On top of this plate is a spaced array provided by a rectangular sheet 14 of paper or hard fiber material is formed. This is preformed with recesses or depressions 15. His Dimensions are essentially equal to the desired thickness of a layer Magnesia cement to be molded into it. Such a material is shown in Fig. 2 shown.

The blade 14 is flexible and has a honeycomb-like configuration.

The layer extends to the top of the mold or slightly above the shape. A foamed magnesium oxychloride cement slurry with a density for example about 0.7 g / cm3 is now introduced.

A second metal plate 12 is then placed on top of the frame laid with a layer of an agent or material that makes it easier to remove is provided. The edges of the second metal plate 12 are in vertical alignment arranged with the first metal plate 12. A second frame 10 is now on the top of the second plate 12 is mounted, the side faces of the frame are arranged in vertical alignment with those of the first frame. To this A number of frames are put together, one frame on top of the other. Each frame is provided with a sheet 14 and with the magnesia cement material filled.

In the embodiment shown in Figure 1, there is a stack formed by five shapes, and on top of the last plate 12 is an upper one Cover panel 16 is arranged, which is identical to the base panel 11. The basic table and the top panels are provided with aligned holes near their perimeter, through which a number of clamping bolts 17 can be passed so that the stack can be pulled together by nuts 18. It is preferred to have a print with Help a press apply to the top panel 16 towards the base panel 11 while tightening the nuts before opening the press again will. The pressing pressure causes the cover sheets to be in intimate contact with the flat the plates 12 are pressed, and that the layer thickness of the magnesia cement through a depth of the sheet 14 is determined which withstands the pressure.

It can be seen from the drawing that the second form in the stack is provided with a top layer on both panel surfaces. This can also so be shaped by placing a top cover sheet on top of the cement slurry is applied before the next top plate 12 is placed.

The arrangement is now left until the cement has hardened or is solidified. During the initial period of the curing process, a chemical reaction takes place during which heat is released. It was unexpectedly found that the excessive heat generation leads to a longer period of time until the formed Articles reach a state of hardness in which the panels are easily handled and can be edited. Performs by cooling the mold during the initial period to the fact that the time it takes to reach the state of strength in which is easy to handle, much abbreviated. Practice the panels 12 perform a cooling function by directing the heat from the molds to the outside where the Heat can be dissipated at the perimeter where the panels overlap the edges of the frames 10. The heat can be dissipated simply or naturally through the ambient air will. The plates themselves can also be cooled, for example, by that cold air is blown over the exposed surfaces. Instead, can also a cold liquid for example water over the exposed Surface are guided. A freezing agent can also be applied, with this Coolant can be passed through channels 19 passing through the plates in the exposed Areas lead. A pump can be used for this purpose. The channels run through the whole Length of the panels.

The plates or frames can also be provided with cooling fins, to increase their exposed surface and thus facilitate cooling.

Experiments have shown that if you make sure that the Material does not assume a higher temperature sufficient to generate significant amounts of steam which usually occurs in the case of magnesium oxychloride cement when a critical temperature of 950 C has been exceeded that then one particularly favorable reduction in curing time and an improvement in quality receives.

It was further found through experiments that if the process described above is carried out without the use of heating plates, the maximum temperature occurs after about four hours. When a cooling is applied will be of the kind that the maximum temperature at the earliest 20% later, i.e. approximately after Five hours occurs, the time it takes the hardening process so far to complete that the panels can be processed, e.g. provided with a veneer can be greatly reduced. That means the molded panels the molding process is much faster for subsequent use happen, so that the effectiveness of the process can be increased. The frame of the form can be removed after 10 to 12 hours, regardless of whether cooling is applied has been or not. When cooling is applied the panels are immediate ready to use for further processing. Without cooling it can be up to 20 Take days before the panels are sufficiently hardened to allow further treatment to suffer. When the cement has set, the panels are removed from the mold, the lining preventing the panels from adhering to the frame 10 and panels 12 sticks.

The method described for molding is when using a panel 13 of honeycomb-like configuration sufficiently resistant to deformation when fire occurs.

The use of a paper or a hard fiber material in the Molding process does not seriously affect the fire resistance of the core, though the paper extends between the opposing surfaces of the panel. A a suitable material as a reinforcement layer is a molded paper or hard fiber layer the kind often used to form the core of hollow doors. Such a material is commercially available under the trade name DUFAYLITE. It can be seen that materials with greater fire resistance than paper or Hard fiber can also be used.

Although the material described has a honeycomb configuration As shown in Figure 2, other configurations for the sheets or layers are possible possible. It is essential that these are provided with recesses or depressions, to form a cellular structure. These can be applied, provided their strength when compressed is sufficient. Examples are the egg carton shape according to FIG. 3 or a mesh-shaped construction.

The magnesia cement used in molding can be a Have densities falling in a range of about 0.2 to 1.0 g / cm3. The bigger the density of the magnesia cement material, the greater the fire resistance and the greater the ability to hold screws tightly. The latter Feature makes it easier to attach hinges, for example, by simply unscrewing them by a thin frame or edge covering that is provided around the panel is and by screwing it into the cement material. Such an edge can e.g. Wood is formed and can be attached to the magnesia cement material during the molding process be molded with.

However, a higher density leads to an increase in weight and the manufacturing cost, and this is disadvantageous.

Usually the design is a compromise between these requirements depending on the particular application. In practice it has a construction of fire doors from such panels with a 4.5 cm thick Layer and a density of 0.35 g / cm3 of fire exposure over half an hour withstood.

In the case of magnesia cement low density panels for Doors, it can be advantageous that a wider frame is molded into it in this way locks, hinges and the like. By screwing only into the To be able to attach frame alone. Such a construction is shown in FIG.

The frame 21 may have inner edges which are shaped so that they improve the hold between the frame and the magnesia cement material. So can the inner edges have longitudinal ribs 22 which are wedge-shaped intervene in the cement material.

A panel can be intermediate bars or rails within the frame exhibit. These bars can have a cross-section similar to that of the frame material.

Instead of using a sheet 14 to ensure the clearance Alternatively, distributed spacers can be used. A possibility is shown in FIG. In this, blocks 23 are of a depth equal to that of the desired one Thickness of the magnesia cement layer provided and in rows at strategic points distributed over the panel. An alternative option is to strip 24 of a Depth equal to the desired thickness of the magnesia cement layer to apply like this Fig. 6 reproduces. Such strips can be arranged in rows of any desired shape be made to specific requirements to suffice. There are many suitable Materials for forming the blocks or strips, e.g. wood or preformed ones Magnesia cement pieces.

For example, of alternative Nagnesia cement materials that are used for which are suitable for use in the manufacture of panels according to the invention the following: magnesium oxysulphate, magnesium oxyphosphate and magnesium oxysulphite. Mixtures Any suitable magnesia cement materials can also be used will.

The magnesia cement can contain suitable additives, e.g.

Fillers such as sand, powdered ash, expanded perlite, cork snippets or granulated cork, plastic or nylon pellets, or vermiculite or the like; fibrous Materials can be provided for reinforcement, e.g. glass fibers, wood wool fibers, Cotton, wool or nylon fibers, hair (as used in plaster of paris and the processed in strand form), as well as pigments.

An alternative construction of a panel is shown in Fig. 7, in this panel a reinforcement is provided around the edges of the panel is. In this arrangement a gain medium is introduced into the mixture and although only around the peripheral area 30 of the panel 31. The reinforcement medlum can take any of the materials mentioned above as an additive. Again, the location of the sheet material 13 applied as desired be, but the sheet can be made wider or shorter to one Frame to leave the perimeter of the mold defined by a frame member 32 is. The parts are coated or coated with a release material. The additives can be introduced into the cement slurry by mixing in the area Area of the frame 32. But they can also be distributed around the perimeter of the frame before the cement material is introduced.

Alternatively, a premixed magnesia cement material of larger Density, e.g. from 0.7 to 1.0 g / cm3 and / or already enriched with reinforcing additives be provided, which is attached in the vicinity of the perimeter of the mold. The rest of the mold can then be coated with a lower density magnesia cement or a Magnesia cement can be filled without additives.

The panels can be covered with cover sheets of any suitable material z. B. hard fibers, wood, plastic or metal provided during the molding process will. These cover sheets adhere to the cement that binds them as it hardens.

The panel is particularly suitable for the manufacture of fire-resistant Gates, partitions, linings and the like.

It can be seen that any suitable means are employed can be used to control the reaction during the initial Hardening process to slow down by cooling. So the process can be carried out in a cooled room will. The frame walls can also have passages through which a cooling liquid is directed.

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Claims (45)

Claims @ panel with a layer of magnesia cement material, esp. as a core filling for doors, partitions, wall cladding or the like., in that the layer is provided with a cover sheet (13) and distributed spacer elements (14, 23,24) is provided, which in the magnesia cement layer are molded in, and that the spacer elements have a depth equal to the thickness of the layer made of magnesia cement and extending from the cover sheet (13) to the opposite Extend the surface of the magnesia cement layer. 2. Panel according to claim 1, characterized in that g e k e n n z e i c h -n e t, that the distributed spacer elements form an integral layer (14) of a material have preformed with recesses or depressions of cellular structure is. 3. Panel according to claim 2, characterized in that g e k e n n z e i c h n e t that the integral layer (14) is preformed like a honeycomb. 4. Panel according to claim 2, characterized in that g e k e n n z e i c h n e t that the integral layer (14) has egg carton-shaped recesses 5. Panel according to one or more of Claims 2 to 4, characterized in that it is not possible c h n e t that the recessed layer is made of cardboard. 6. Panel according to claim 1, characterized in that g e k e n n z e i c h n e t the distributed spacer elements comprise a series of block elements (23). 7. Panel according to claim 1, characterized in that g e k e n n z e i c h n e t that the spacers comprise a series of strips (24). 8. Panel according to one or more of claims 1 to 7, characterized It is not noted that the cement material comprises magnesium oxychloride. 9. Panel according to one or more of claims 1 to 7, characterized It is not noted that the cement material comprises magnesium oxysulfate. 10. Panel according to one or more of claims 1 to 7, characterized It is not noted that the cement material comprises magnesium oxyphosphate. 11. Panel according to any one of claims 1 to 7, characterized in that g e -k It is noted that the cement material comprises magnesium oxysulfite 12th Panel according to one or more of the preceding claims, characterized in that It is noted that the magnesia cement material comprises a filler material. 13. Panel according to one or more of the preceding claims 1 to 12, noting that the magnesia cement material is a comprises fibrous reinforcing material. 14. Panel according to one or more of claims 1 to 13, characterized it is not noted that the magnesia cement material contains a dye. 15. Panel according to any one of the preceding claims 1 to 14, in that the magnesia cement material has a density in the range between about 0.2 to 1.0 g / cm3. 16. Panel according to one or more of claims 1 to 15, characterized it is noted that the cover sheet (13) is on both surfaces of the layer made of magnesia cement is provided, such that the spacer elements (14,23,24) extend continuously between the two cover sheets (13). 17. Panel according to one or more of the preceding claims 1 up to 16, due to the fact that in Panel circumference area (30) the magnesia cement contains a reinforcing additive. 18. Panel according to one or more of claims 1 to 16, characterized it is noted that it has a molded-in peripheral frame (21). 19. A method for producing a panel in a form according to a One or more of Claims 1 to 18, characterized in that Spacers (14,23,24) distributed in the mold and then a magnesia cement slurry filled in and a cover sheet (13) is introduced on at least one side, whereupon the mass between the large areas (12, 13) are compressed to form the sludge between the cover sheet and the opposite side until the Spacer elements (14,23,24) are in intimate contact between the compacting surfaces (12:13), whereupon the mud is allowed to harden. 20. The method according to claim 19, characterized in that g e k e n n z e i c h -n e t that the two cover sheets (13) in the form (10) on the bottom and on the top the mold are placed in such a way that the cement slurry is enclosed between the surfaces is, and that a cover sheet (13) is used as a compression surface. 21. The method according to claim 19 or 20, characterized in that g e k e n n -z e i c h n e t that the heat build-up occurs during an initial curing period Cooling is controlled. 22. The method according to claim 21, characterized in that that the cooling is carried out so that the temperature is below an evaporation temperature lies. 23. The method according to claim 21, characterized in that it is e k e n n z e i c h -n e t that the cooling is carried out in such a way that the temperature of the Molding material is kept at a value not higher than 950C. 24. The method as claimed in claim 21, characterized in that it is e k e n n z e i c h -n e t that the cooling is carried out so as to increase the time which it takes when the molding material reaches its highest temperature value, and this Time elongation takes place by about 20%. 250 The method according to one or more of claims 21 to 24, characterized It is not stated that the heat that is generated can be exposed to the outside through the shape discharges0 26. The method according to one or more of claims 21 to 25, characterized it is noted that cooling is achieved by dissipating heat through a Base plate (12) and a cover plate (12) takes place. 27. The method according to one or more of claims 21 to 26, characterized It is not noted that the heat is removed from the mold by direct dissipation is discharged into the atmosphere. 28. The method according to one or more of claims 21 to 26, characterized It is not noted that the heat is dissipated by means of forced cooling he follows. 29. The method according to claim 28, characterized in that it is e k e n n z e i c h -n e t that the forced cooling takes place with the aid of a fluid that is passed over the molds will. 30. The method according to claim 28, characterized in that that the forced cooling by the passage of a cooling fluid through the interior the plates (12) takes place. 31. The method according to claim 29 or 30, characterized in that g e k e n n -z e i c h n e t that the fluid is a coolant. 32. The method according to one or more of claims 19 to 31, characterized It is not noted that one can use the magnesia cement material with a density used in the range between 0.2 to 1.0 g / cm3. 33. The method according to claim 32, characterized in that it is e k e n n z e i c h -n e t that the magnesia cement material is foamed before hardening. 34. The method according to one or more of claims 19 to 33, characterized it is not noted that a peripheral frame (21) is inserted for the panel and the magnesia cement is introduced into the frame. 35. The method according to one or more of claims 19 to 34, characterized it is not noted that spacing elements can be in the form of rows of Arranges blocks (23). 36. The method according to one or more of claims 19 to 34, characterized It is not noted that a layer is used to form the spacer elements (14) made of a material that was previously provided with recesses or depressions provides in the manner of a cellular structure. 37. The method as claimed in claim 36, characterized in that it is e t that the layer (14) is provided with recesses in the form of an egg carton. 38. The method as claimed in claim 36, characterized in that it is e k e n n z e i c h -n e t that one forms the layer (14) with recesses in the honeycomb type. 39. The method according to one or more of claims 19 to 38, characterized it is not indicated that a cover sheet (13) on the base of the form (10) before inserting the magnesia cement and the spacer elements (14,23,24). 40. The method as claimed in claim 39, characterized in that it is e k e n n z e i c h -n e Don't put a cover sheet on top of the magnesia cement material in the mold (10) is applied before pressure is applied to the surface and before the Lets cement harden. 41. The method according to one or more of the preceding claims 19 to 40, indicated by the fact that a reinforcing additive is used Introduces into the magnesia cement, limited to the area on the perimeter (30) the form. 42. Device for carrying out the method according to one of the claims 19 to 41, in which a frame is provided to determine the outline of the panel is, in that a cooling plate (12) is placed on the frame (10) can be placed with the help of which heat can be removed from the mold. 43. Panel forming device according to claim 42, characterized in that g e -k e n n z e i c hn e t that the plate (12) overlaps the edges of the mold framework (10). 44. Panel forming device according to claim 42 or 43, characterized g e k It is noted that the plate (12) has passages (19) for a cooling fluid is provided. 45. Panel forming device according to claim 44, characterized in that it is not i c h n e t that a forced circulation device (20) for generating a coolant flow is provided by the plate (12).