EP2612979A2 - Door leaf and production method - Google Patents

Abstract

The door leaf (10) is formed from two metal sheets (200,202) forming a cavity (204) between the metal sheets and a door panel (206) in the cavity. The door panel is bonded with the metal sheets. The former metal sheet is bonded with the door panel in certain areas with a bonding pattern (208) formed from bonded- and unbonded areas. The latter metal sheet is bonded with the door panel in certain areas with another bonding pattern (212) formed from bonded- and unbonded areas. The two bonding patterns are formed in a different manner. Independent claims are included for the following: (1) a door with a frame; and (2) a method for manufacturing a door leaf.

Description

The invention relates to a door leaf, in particular for a multifunction door, which has at least one first metal sheet and at least one second metal sheet and a door panel inserted in a door leaf cavity between the metal sheets, and a manufacturing method for such a door leaf. Moreover, the invention relates to a door provided with such a door leaf, in particular multifunctional door. The invention particularly relates to a door leaf in a box-lid construction, wherein the first and the second metal sheet are formed as a box sheet and cover sheet.

In the DE 199 34 680 C2 is described a door leaf with circumferential fold area, in which a vorgefälztes already in the four edge areas box plate and a non-folded cover sheet are placed on each other and then connected by bending the cover plate to form a Dickfalzes. Thus, at least three process steps for the production of the door leaf are necessary, namely a first Umfälzschritt, the joining and a second Umfälzschritt after assembly.

In the DE 10 2005 023 426 B3 discloses a method in which both a box plate and a thick-seamed cover sheet in the edge region, but not in the rebate, haken hook profiles hooked into one another for connection of the box with the cover sheet. After hooking the hook profiles are mutually displaced.

In the DE 10 2008 056 502 A1 a groove is provided in a box panel of a door leaf in the edge region, which has holes on a leg lying in the inside of the box plate. A cover plate has in the edge region springs which engage in the groove, wherein at the end of the springs Hooks are provided, which engage in the assembly of box and lid in the holes. The two profiles are connected by placing the cover sheet on the box sheet and then squeezing the two sheets together so that the springs are pressed deeply into the grooves and the hooks snap into the holes.

The WO 82-04281 discloses a door leaf with two symmetrically formed door panels. The door panels have to each other to be straightened corners Umgreifungen over which the door panels are interconnected. The resulting door leaf is formed without fold due to the symmetrical design of the door panels.

The GB 2 254 872 A shows a dull executed door leaf. The lateral edge regions of a box and a cover plate, which form the corners of the door leaf after connection, are bent so that they engage in accordance with a tongue and groove connection.

In the documents DE 35 34 233 A1 . US 1 848 715 . DE 35 20 500 A1 such as DE 28 11 142 A1 Door leaves are disclosed in which a box and a cover plate are connected to each other via interlocking engagement means in the edge region, but not in a rebate area.

The DE 24 37 261 A1 discloses a door leaf in a box-lid construction, in which an edge region of the box is supported on a rebated to a fold region edge region of the lid, so as to form a firm connection of the box and lid. The connection is made by compressing the box into the lid.

In the EP 09 89 277 A2 a door leaf is disclosed in which a box panel and a cover plate are often bent so that they engage inside a folding area behind the other and that the folding area is arranged spaced from the actual door leaf.

The CH 36 55 19 describes a door leaf in which a plurality of curved stiffening plates are welded to the side edges of the door panels, so as to keep an inserted between the door panels insulating in place.

In all of the aforementioned known door leaves in box-lid construction usually the door panel is placed loose in the box, and then the lid is firmly connected to the box. The cohesion of the door leaves via the connection of box plate and cover sheet along the edge regions. To fulfill special functions, such as Burglary protection or fire protection functions, known door leaves must be stiffened separately, for example by a separate frame in the door leaf, by separate stiffening profiles or by separate inserts, such as e.g. Strip of stiff material.

The object of the invention is to provide a made of at least two metal sheets with filling between them formed door leaf, which is easy and inexpensive to mass produce, a high quality appearance, especially a large planarity of broadsides, provides and has high Schalldämmfähigkeiten.

This object is achieved by a door leaf having the features of claim 1 and a manufacturing method for producing such a door leaf according to the independent claim.

Advantageous embodiments of the invention are the subject of the dependent claims. In addition, a door provided with such a door leaf is proposed.

According to a first aspect thereof, the invention provides a door leaf formed from a first metal sheet, a second metal sheet forming a cavity therebetween, and a door panel in the cavity, the door panel being bonded to the first and second metal sheets, the first one Metal sheet with a glued surfaces and unglued surfaces formed first gluing pattern is partially glued to the door panel, wherein the second metal sheet is adhesively bonded in regions with a second adhesive pattern formed from bonded surfaces and unglued surfaces.

Preferably, the first metal sheet is a box sheet, which box-like forms the largest part of the cavity, and the second metal sheet is a cover sheet for covering the cavity mainly formed by the box. Further preferably, the first metal sheet and the second metal sheet are firmly connected to each other at all four edge regions of the door leaf.

In particular, with the construction according to the invention a door leaf is created in so-called sandwich construction. The door leaf itself is similar to a sandwich panel constructed such that the metal sheets are connected to the door panel itself distributed over the wide area, in particular by gluing. In a preferred embodiment, the metal sheets as a box sheet and cover sheet and the door panel is designed in sandwich construction. In sandwich construction box panel, cover plate and door panel are more or less rigidly connected to each other, in particular by as large as possible or as large as possible distributed bonding.

A sandwich construction is particularly interesting for doors with heavy mechanical stress. For example, fire doors in the course of a fire by the different temperature load and the consequent different expansions of the metal sheets of strong tension that lead to bending of the door leaf. Also for burglary-resistant doors as stiff as possible door leaf is desired. In previously known fire doors and / or burglar-resistant doors box-lid construction has therefore introduced additional stiffeners, for example, has been provided separate metal profiles or metal frame for reinforcing the edge regions, which have been introduced in addition to the metal sheets in the cavity. This has made the production of both the additional material and because of further steps for producing the stiffening expensive and the weight increased. Increased weight leads to difficult handling and more expensive assembly, eg Lifting tools are needed, and to increase transport costs. On the other hand, if you consider a rigid surface connection between the metal sheets and the filling insert, you can dispense with separate stiffeners in the edge region, such as other metal inserts, etc., which simplifies production and assembly and saves material and transport costs.

Next, the flatness is improved due to a flat rigid and / or large area distributed connection between the respective metal sheet and the door panel in the door panel itself. Especially when using high-quality reflective outer surfaces and smaller deviations of the door leaf broadside of the optimal level are visible; Improving the planarity results in a higher quality appearance.

The Applicant has therefore developed a door leaf in sandwich construction in internal tests, wherein the broad sides forming metal sheets are glued over the entire broadside with the door panel over the entire area. The door leaf has turned out to be excellent in terms of the required properties of a rigid construction even without additional stiffening insert as well as in terms of the desired planarity. Even fire tests in a version as a fire door panel have been successful. However, when testing the soundproofing values of the new design, it has been found that the soundproofing value has deteriorated considerably compared to previously known door leaf constructions in box-lid construction.

With the preferred solution here all the advantages of a sandwich construction for door leaves in box-lid construction and additionally good sound insulation values are achieved.

Sound values are checked, for example, by applying a so-called pink noise to the door provided with the door leaf. In particular, vibrations with very different frequencies in the frequency range of low sound frequencies up to very high sound frequencies are created on one side, and then it is measured on the sound side of the door, which sound powers are transmitted.

For full-surface glued door leaves has been found that, especially in a frequency range of about 500 Hz is a slump in the sound insulation, or even several burglaries on the different frequencies away. Due to the inherently stiffer construction, the soundproofing value has thus deteriorated.

In previous door leaf constructions of the Hörmann KG Freisen with conventional box-lid construction, it was very easy to achieve a soundproof door by minor modifications, for example, adding additional seals. It was therefore possible to make a soundproof door out of a standard door with only a few additional elements.

However, with the solution according to the invention of only partial bonding according to specific bonding patterns, the advantages of the sandwich construction can be achieved with the earlier simple upgrade to the soundproof door.

In order to achieve the advantage of a simple upgrade to the soundproof door leaf with optimum effect, different gluing patterns have been tested.

It has been found to be advantageous for the sound insulation value when the first and the second adhesive pattern are formed differently. Particularly preferably, the first and the second bonding pattern, although similar, but executed inversely to each other. As a result, a mutual bonding can be achieved in a simple manner.

Preferably, it is provided that, seen in plan view of a broad side of the door leaf, bonded surfaces of a gluing pattern overlap with unglued surfaces of the other gluing pattern.

In particular, alternating sequences of bonded surfaces and unglued surfaces have been found to be advantageous for increasing the sound insulation.

It is therefore preferred that glued and unglued surfaces, viewed in a vertical and / or horizontal direction over the gluing patterns, are arranged alternately side by side.

It is particularly preferred that glued and unglued surfaces are provided in checkerboard-like fields in at least one of the gluing patterns.

The best soundproofing value in previously studied adhesive patterns has been achieved in a kind of checkerboard bonding pattern where on the one fields - corresponding to, for example, the white fields of a chessboard - on the side of the first metal sheet, e.g. on the box side, and on the remaining other fields - corresponding to, for example, the black boxes of a chess board - on the side of the second metal sheet, e.g. on the cover side, is glued.

The fields do not have to be distributed like a checkerboard. The surfaces to be joined are preferably divided into rows and columns into different fields fields with gluing and fields without gluing - which are provided alternately both in rows and in columns. Preferably, similar but inverse field distributions are provided on both sides - connection to the first metal sheet on the one hand and connection to the second metal sheet on the other hand.

The gluing fields do not have to be fully glued. It has been found that only partial bonding is advantageous. For example, each field with adhesive has a bond strip, which extends in one dimension - eg width or height of the field - across the whole field and covers only a portion of the field in the second dimension. at For example, a checkerboard pattern is preferred in that each glued panel has a central bondline vertically overlapping the entire height of the panel, but whose width is only a fraction of the width of the panel. For example, the extent of the adhesive strip is between 10% and 80%, preferably between 15% and 30% and in particular 25% of the extent of the field to be bonded. Due to the width, arrangement and orientation of the adhesive strip per field, different sound insulation properties can be achieved. The optimal arrangement can be achieved by a few attempts depending on the desired Schalldämmfunktion.

In particular, a mutual bonding is preferred, which makes the construction acoustically soft overall, since the door panel is glued only on one side each and can dodge on the other side.

At peripheral areas, however, such a gluing pattern with only partial gluing may be disadvantageous for fire protection. To accommodate the bracing forces are for door leaves for fire doors stiffer edge areas and in particular a particularly rigid construction in the upper part of the built door desired. Since heat rises upwards, the upper edge region of the region which in the case of fire is usually the most heavily loaded, is why a particularly rigid connection in this upper region is preferred.

According to a preferred embodiment, it is therefore provided that at least one edge region, in particular on an edge region to be arranged horizontally above, a full-surface bonding between sheet metal and door panel is provided, which is formed over a larger area than the adhesive bonding within the associated adhesive pattern.

For further stiffening and simplifying the production, it is further preferred for the metal sheets to hook behind one another at edge regions

Profilings are provided and are connected by a Hinterhakung the profiles with each other.

The invention also relates to a door, in particular fire door with sound insulation function, characterized by a door leaf according to one of the above aspects and a frame.

• Bereitstellen eines ersten Metallblechs und eines zweiten Metallblechs, wobei die Metallbleche derart gestaltet werden, dass sie zwischen sich einen Türblatthohlraum definieren,
• Bereitstellen einer Türfüllung zum Füllen des Türblatthohlraums,
• bereichsweises Verkleben der Türfüllung mit einem ersten Verklebemuster mit dem ersten Metallblech und
• bereichsweises Verkleben der Türfüllung mit einem zweiten Verklebemuster mit dem zweiten Metallblech.

Further, according to another aspect of the invention, the invention provides a manufacturing method for manufacturing a door panel, comprising the steps of:

• Providing a first metal sheet and a second metal sheet, wherein the metal sheets are configured to define a door leaf cavity therebetween,
• Providing a door panel for filling the door panel cavity,
• area-wise gluing the door panel with a first gluing pattern with the first metal sheet and
• area-wise gluing the door panel with a second gluing pattern with the second metal sheet.

It is preferable that the first and second bonding patterns are formed differently. Particularly preferably, the first and the second bonding pattern, although similar, but executed inversely to each other. As a result, a mutual bonding can be achieved in a simple manner.

According to a further embodiment of the method is preferred that seen in plan view of a broad side of the door leaf, the first metal sheet is glued to surface areas with the door panel, where the door panel and the second metal sheet remain unglued and / or seen in plan view of a broad side of the door panel the second metal sheet is glued to surface areas with the door panel, where the door panel and the first metal sheet remain unglued.

It is particularly preferred that over a vertical and / or across a horizontal direction across alternating fields with bonding and fields without Gluing be provided between the door panel and the respective metal sheet. Preferably, the door panel and the respective metal sheet remain loose in the fields without gluing and are not connected there.

It is therefore particularly preferred that for joining the metal sheets and the door panel, the respective interface between metal sheet and door panel is divided into fields with bonding and fields without gluing such that fields with bonding and fields without gluing alternate both column by column and row by row with each other, the glued panels preferably having an adhesive strip which extends across the field in one dimension and has a smaller extension in the other dimension than the adhesive field.

The fields can have different shapes. In order to achieve a simple uniform distribution across the interface, it is preferred to have molds which can be uniformly distributed over a surface, e.g. Squares, equilateral triangles, regular hexagons, regular octagons, etc. The fields can all be configured the same or even differently in some areas.

Preferably, it is provided that the first and / or the second metal sheet are glued like a checkerboard with the door panel, in particular in mutual bonding.

It is preferred that at least one of the metal sheets is adhesively bonded to the entire surface of the door panel on at least one edge region of the door leaf, in particular on an edge region to be arranged horizontally above.

Preferably, an upper surface portion of the interface between the door panel and sheet metal extending from the top horizontally to be arranged edge of the door panel to a part of its height extent, for example, 5%, 10%, 15% or 20% or intermediate values thereto, and extending in horizontal width direction (when using the door leaf as intended) extends over the entire width of the door panel, glued over the entire surface. As a result, a particularly rigid construction over the entire door leaf width is achieved in this upper edge region to counteract tension in case of fire in this area.

It is particularly preferred that the metal sheets are provided at the edge areas with Hinterhakungsprofilen for mutual Hinterhakung and that the metal sheets are pushed after insertion of the door panel in one of the metal sheets and applying adhesive according to the particular pattern of adhesion with hinterhakenden Hinterhakungsprofilen each other. By this type of Hinterhakung can be a particularly simple installation of the metal sheets reach. Hinterhakungsprofile can still be made relatively easily on rolling tools or the like on the individual metal sheets, so that even more complicated Hinterhakungsprofilformen be formed on the edge regions. It can be so without post-processing steps or possibly only with minor post-processing steps, for example, additional pressing or compressing the Hinterhakungsprofile after pushing the metal sheets, worked.

Although a checkerboard pattern has proved to be particularly effective for sound insulation in tests as a gluing pattern, the invention is not limited to this gluing pattern. Different gluing patterns can be used. Preferably, alternating patterns are provided with glued fields and unglued fields. Particularly preferably, the first and the second bond pattern are complementary to each other, so that where the first bond pattern a bonded surface area is provided in the second bond pattern, a surface area without connection between metal sheet and filling is provided and vice versa. In particular, a mutual regional bonding is provided with different patterns.

An advantage of the bonding proposed here is also that material can be worked within the filling material. It can also be a single one uniform material filling over the entire wide area - eg insulation mat based on mineral fiber material, such as with at least one or more mineral fiber wool layer (s) - are provided; or the filling can be turned off entirely to an essential function, such as the fire protection function, without worrying about the sound function. This filling can then be made acoustically soft by regional bonding.

In the following, further advantageous embodiments of the manufacturing method and the door leaf are explained.

The gluing patterns are particularly preferably used in a method for producing a door leaf at least two-sided rebated from sheet metal in box and lid construction and in such a door leaf.

Folded door leaves have the advantage that they lie with the door closed over a projection on the door frame. Since there is no visible gap between the door leaf and the frame, these doors usually provide better heat and sound insulation than door leaves with blunt termination and are particularly suitable for use in fire doors.

In previously known rebated door leaves while Hinterhakeinrichtungen are known, via which a box panel can be connected to a cover plate, but these are usually not in the rebate area, but arranged in an edge area next to the fold. Such an arrangement makes the connection visible, which is often undesirable for optical reasons and prone to adverse external influences.

However, when the rear hooks are arranged in the fold area itself, this often leads to complex connection methods, since with circumferential Hinterhakungen on all four sides of the door leaf, the sheets must first be pre-bent, then placed on each other and then processed to form the fold area further by be bent over again.

Therefore, advantageous embodiments of the invention aim to provide a method for producing a visually appealing door leaf in box and lid construction, which is simple and inexpensive to manufacture, or to provide a corresponding optically high quality door leaf.

1. a) Bereitstellen eines Kastenbleches und eines Deckelbleches zum Bilden von Kasten und Deckel;
2. b) Umfälzen von zwei parallelen Randbereichen an entsprechenden parallelen Rändern des Kastenbleches und des Deckelbleches, um einander in Längsrichtung der Randbereiche verschiebbar hintergreifende Hintergreifeinrichtungen innerhalb zweier paralleler Türfalze zu bilden;
3. c) Umfälzen wenigstens eines dritten Randbereichs von Kastenblech und Deckelblech, so dass an einem der Bleche eine Aufnahmenut und an dem anderen der Bleche eine in die Aufnahmenut in Verschieberichtung einführbare Feder entsteht;
4. d) Zusammenfügen von Kastenblech und Deckelblech durch Ineinanderhaken der Hintergreifeinrichtungen und Verschieben, bis die Feder in die Aufnahmenut eingreift.

Particularly preferred for joining the metal sheets, a method for producing a rebated door panel of metal sheets in box and lid construction is provided, comprising the following steps:

1. a) providing a box plate and a cover plate for forming box and lid;
2. b) refolding two parallel edge regions at respective parallel edges of the box plate and the cover plate to form behind each other in the longitudinal direction of the edge regions slidably engaging behind rear gripping means within two parallel Türfalze;
3. c) refolding at least a third edge region of the box plate and the cover plate, so that a receiving groove is formed on one of the plates and on the other of the plates a spring which can be inserted into the receiving groove in the direction of displacement is produced;
4. d) joining the box plate and cover sheet by hooking the rear gripping devices and moving until the spring engages in the receiving groove.

The structure with letters a), b) c) and d) is chosen purely for the sake of simplicity and contains no statement about a particular order. In particular, the order of steps b) and c) is arbitrary.

With such a method, a door leaf is formed, which has a folding area on at least three sides, which seals the door frame after installation of the door leaf in a door frame. Thus, the door is particularly suitable as a fire door.

The connections lie in the fold areas and are therefore not exposed to negative influences from the outside or not visible.

The rear gripping devices at the edge regions of the box plate and the cover plate are designed such that they are nevertheless displaceable in the longitudinal direction against each other during manufacture, after they have been interengaged behind each other. So can be placed on the box plate and the two sheets are interconnected by moving against each other just after already carried out Umfälzen the edge regions of the cover sheet. Advantageously, can be dispensed with further forming steps. For example, Another refolding in the folding area is no longer necessary. The entire process is thus simpler and less expensive.

In a third edge region, which is arranged orthogonally to the first two parallel edge regions, a receiving groove is provided on one of the sheets and on the other of the sheets a spring. The term "spring" is understood to mean an engagement arrangement designed to engage in a groove in the manner of a tongue and groove connection. When moving the box plate against the cover plate, the spring is inserted into the receiving groove and thus the sheets are also closely connected in the third edge region. Again, the connection is already before assembly of the sheets, e.g. by refolding of the sheets present, preferably in such a way that no further forming steps after joining are more necessary.

Preferably, a fourth edge region of the box plate and cover plate is folded over so that a second receiving groove is formed on one of the plates and a second spring which can be inserted into the receiving groove in the direction of displacement is formed on the other of the plates. Thus, a firm connection between the box and cover sheet is also provided in a fourth fold area, which nevertheless advantageously makes it possible to provide the solid compound of box and cover sheet by merely folding and subsequent insertion. The fourth edge region preferably runs parallel to the third edge region and orthogonal to the first two parallel edge regions.

• d1) Auftragen einer Kleberschicht auf das Kastenblech zwischen den umgefälzten vier Randbereichen;
• d2) Einlegen einer Isoliereinlage auf die Kleberschicht; und/oder
• d3) Auftragen einer Kleberschicht auf die Isoliereinlage auf.

In a particularly preferred embodiment, step d) comprises at least one of the steps

• d1) applying an adhesive layer to the box panel between the folded four edge areas;
• d2) inserting an insulating insert on the adhesive layer; and or
• d3) applying an adhesive layer to the insulating insert.

The door leaf can thus preferably be equipped with fire protection material by simply gluing an insulating insert between the box and cover plate. Furthermore, the connection is advantageously also narrower if additional adhesive layers are introduced. Thus, it is advantageously avoided that the door leaf must be welded, riveted and / or screwed at any point in the process, and the production is further simplified and cheaper.

In particular, the adhesive layers are applied only in certain areas in predetermined bonding patterns, as explained above.

A further advantageous embodiment of the invention provides a door leaf with a box and a cover plate, which at two parallel edge regions on corresponding parallel edges of the box and cover plate has slidably engaging behind each other in the longitudinal direction of the edge regions engaging behind, wherein at a third edge region of the sheet one Receiving groove and on the other of the sheets one in the receiving groove in the direction of insertion insertable spring is formed.

Such a door leaf is particularly easy to produce with the method described above and requires only two process steps, namely the Umfälzen the first, second and third edge regions and then the juxtaposition and against each other moving box and lid, so that the box and cover plate to the door leaf get connected.

Advantageously, a first rear engagement device is designed as a first U-profile with an inner leg, an outer leg and a first web therebetween. Particularly preferably, the outer leg is angled at an angle greater than 90 ° to the first web. The U-profile is thus advantageously angled inward and a counterpart can be supported on the inwardly angled outer leg.

Preferably, a second rear gripping device is designed for gripping around the first rear gripping device. In this case, the second rear engagement device is advantageously formed as a second U-profile with an upper leg, a lower leg and a second web therebetween, wherein on the lower leg an angled portion is formed by more than 90 ° inwards. This bend can be easily supported on the outer leg of the first U-profile. Since the second rear gripping device further surrounds the first rear gripping device and thus advantageously also the outer leg, the two sheets can be easily connected to each other by the first U-profile is inserted into the second U-profile.

Preferably, the angled portion is angled at the same angle as the angle between the first web and the outer leg, the outer leg and the bend are parallel to each other and are supported against each other. They can be arranged particularly close to one another without an undesired entanglement occurring during the displacement, which prevents the box from being moved further to the cover plate. Nevertheless, a tight connection between the box and the cover plate is preferably ensured by the close concern of the bend and the outer leg.

In a particularly preferred embodiment, the bend is formed on an envelope of the lower leg. If the lower leg of the second U-profile advantageously has an envelope, it becomes more resistant to bending. The stability is transferred overall via the bend on the entire rebate area of the door leaf, so that the envelope not only the lower leg of the stabilized second U-profile, but also advantageous at the same time the entire rebate area of the door leaf.

The first U-profile is preferably designed to encompass the bend. Thus, not only the second U-profile surrounds the first U-profile and forms a first connection, but the first U-profile also surrounds a part of the second U-profile, so that a second connection is present. This makes the connection of box and cover plate preferably particularly firm.

Particularly preferably, the first rear gripping device is formed on the box plate and the second rear gripping device on the cover plate. Thus, the rear gripping devices can be arranged in the folding area, without resulting on the broad sides of the box or the cover plate projections by folded edge areas of the sheets.

Preferably, a fourth edge region of the box and the cover plate is folded over, wherein on one of the sheets a second receiving groove and on the other of the sheets a in the receiving groove in the direction of insertion insertable second spring is formed. Thus, the door leaf is formed not only on the long sides, but also on both end sides by firm connection of the box and cover plate together.

Advantageously, the third edge region is folded over to a third U-profile having a first straight leg, a receiving leg and a third web therebetween, wherein the first receiving groove is formed on a second envelope on the receiving leg, wherein the fourth edge region to a fourth U-profile is folded over with a spring leg, a second straight leg and a fourth bridge between them, wherein the second spring is formed by the spring leg.

Thus, envelopes are provided on one of the sheets on the third and fourth edge region, which advantageously increase the stability of the connection in the fold region. The U-profiles are here preferably configured rectilinear, ie the Legs of the U-profiles are arranged substantially parallel to each other. Thus, it is preferably prevented that an entanglement occurs during the pushing together of the box and cover sheet and prevents complete telescoping of the sheets.

Fig. 1

einen Horizontalschnitt durch ein Türblatt;

Fig. 2

einen Vertikalschnitt durch das Türblatt;

Fig. 3

ein Kastenblech zum Bilden des Türblatts;

Fig. 4

ein Deckelblech zum Bilden des Türblatts;

Fig. 5

das Kastenblech aus Fig. 3 mit eingebrachten Verstärkungen;

Fig. 6

das Kastenblech aus Fig. 5 mit Kleberschicht;

Fig. 7

das Kastenblech aus Fig. 6 mit auf die Kleberschicht aufgelegter Isoliereinlage;

Fig. 8

das Kastenblech aus Fig. 7 mit einer auf die Isoliereinlage aufgebrachten weiteren Kleberschicht sowie das Deckelblech aus Fig. 4;

Fig. 9

das Türblatt mit teilweise zusammengeschobenem Kastenblech und Deckelblech;

Fig. 10

das Türblatt mit fast vollständig zusammengeschobenem Deckelblech und Kastenblech;

Fig. 11

das Türblatt aus Fig. 1 mit vollständig zusammengeschobenem Kasten- und Deckelblech;

Fig. 12

einen Längsschnitt durch das Türblatt in der Situation der Fig. 10;

Fig. 13

eine Ansicht auf eine erste Ausführungsform einer mit dem Türblatt versehenen Tür von der Deckelblech-Seite aus gesehen mit angedeutetem Verklebemuster zwischen Deckelblech und Isoliereinlage;

Fig. 14

eine Ansicht auf die Tür von Fig. 13 von der Kastenseite aus gesehen mit angedeutetem Verklebemuster zwischen Kastenblech und Isoliereinlage;

Fig. 15

eine schematische Darstellung eines Verklebemusters einer weiteren Ausführungsform des Türblattes auf der Kastenseite; und

Fig. 16

eine schematische Darstellung des Verklebemusters des Türblatts von Fig. 15 auf der Deckelseite.

Embodiments of the invention will be explained in more detail with reference to the accompanying drawings. It shows:

Fig. 1

a horizontal section through a door leaf;

Fig. 2

a vertical section through the door leaf;

Fig. 3

a box panel for forming the door panel;

Fig. 4

a lid sheet for forming the door panel;

Fig. 5

the box sheet Fig. 3 with added reinforcements;

Fig. 6

the box sheet Fig. 5 with adhesive layer;

Fig. 7

the box sheet Fig. 6 with applied on the adhesive layer insulating insert;

Fig. 8

the box sheet Fig. 7 with a further adhesive layer applied to the insulator insert and the cover plate Fig. 4 ;

Fig. 9

the door leaf with partially pushed together sheet metal and cover sheet;

Fig. 10

the door leaf with almost completely pushed together cover plate and box sheet;

Fig. 11

the door leaf off Fig. 1 with completely pushed together box and cover plate;

Fig. 12

a longitudinal section through the door leaf in the situation of Fig. 10 ;

Fig. 13

a view of a first embodiment of a door provided with the door leaf seen from the cover sheet side with indicated Verklebemuster between the cover plate and insulating insert;

Fig. 14

a view on the door of Fig. 13 seen from the box side with indicated Verklebemuster between the box plate and insulating insert;

Fig. 15

a schematic representation of a gluing pattern of another embodiment of the door leaf on the box side; and

Fig. 16

a schematic representation of the gluing pattern of the door leaf of Fig. 15 on the lid side.

Fig. 1 shows a cross section (horizontal section) through a door leaf 10 for a multifunctional door, and Fig. 2 shows a longitudinal section (vertical section) through the door leaf 10. The door leaf 10 has a first metal sheet 200 and a second metal sheet 202, which form a cavity 204 therebetween, which is filled with a door panel 206. The door panel 206 is adhesively bonded to the first metal sheet 200 only partially with a first adhesive layer 106 applied in a first adhesive pattern 208, and only partially adhesively bonded to the second metal sheet 202 with a second adhesive layer 106a applied in a second adhesive pattern 212. The gluing patterns 208, 212 will be explained in more detail below.

The door leaf 10 has as a first metal sheet 200, a box plate 12 and a second metal sheet 202, a cover plate 14, which in each case two parallel Edge regions 16, 18 are interconnected. The first edge regions 16 and the second edge regions 18 are each folded over in order to form rear gripping devices 20, 21. Since the rear gripping devices 20, 21 are formed on the first edge region 16 symmetrically to the rear gripping devices 20, 21 on the second edge region 18, only the rear gripping devices 20, 21 on the first edge region 16 will be described below.

The box plate 12 is folded over to form a box 22 and further comprises at its first edge portion 16, which is formed on a hinge side 23, by crimping a first U-profile 24. The first U-profile 24 is defined by an inner leg 26, an outer leg 28 and a first web 30 therebetween. The outer leg 28 of the first U-profile 24 is angled relative to the first web 30 by more than 90 ° and thus aligned obliquely in the direction of the inner leg 26.

The cover plate 12 is angled to form a lid 32 and has at its first edge region 16 by bending a second U-profile 34. The second U-profile 34 is defined by an upper leg 36, a lower leg 38 and a second web 40 therebetween. The lower leg 38 has an angled portion 42 which is bent inwardly at an angle greater than 90 ° relative to the lower leg 38. Thus, the angled portion 42 is directed toward the upper leg 36 in the interior of the second U-profile 34.

In addition, the lower leg 38 has a first envelope 44, at the end of the bend 42 connects.

The first U-profile 24 and the second U-profile 34 are thus designed such that they can engage behind each other, so that the first U-profile 24, the first rear gripping device 20 and the second U-profile 34, the second rear gripping device 21 is formed. The first U-profile 24 engages with the angled outer leg 28, the bend 42, which is formed on the second U-profile 34. At the same time, the second U-profile 34 engages with the upper one Leg 36, the lower leg 38 and the second web 40, the first web 30 and the outer leg 28 of the first U-profile 24th

The bend 42 and the outer leg 28 are based - in particular under bias - from each other and thus form a close connection of the box plate 12 with the cover plate 14. This is supported by the oblique course of the two outermost free edge strips (angled 42 and leg 28) ,

Furthermore, a lock 46 with a catch 50 on a longitudinal end face 52, the lock side 53, is provided on the illustrated door leaf 10.

Due to the illustrated embodiment of the rear gripping devices 20, 21, they can interlock and thus connect the box plate 12 with the cover plate 14. During assembly remain, despite this rear handle, the box plate 12 and the cover plate 14 but in the longitudinal direction against each other.

In Fig. 2 showing the longitudinal section (vertical section) through the door leaf 10, the longitudinal direction, in which the box plate 12 and the cover plate 14 are mutually displaceable during assembly, indicated by an arrow 48.

At a third edge region 54 - in this case the edge region to be arranged horizontally above - the box plate 12 and the cover plate 14 are folded over in such a way that a first tongue and groove connection 56 is formed. For this purpose, a first receiving groove 58 is formed on the cover plate 14 on the third edge region 54.

The third edge region 54 of the cover plate 14 is folded over to form a third U-profile 60 and has a first straight leg 62, a receiving leg 64 and a third web 66 therebetween. The receiving leg 64 is provided with a second envelope 68 for forming the first receiving groove 58. At the end of the second envelope 68, the first receiving groove 58 is formed by further refolding of the receiving leg 64. The receiving groove 58 has an upper groove leg 70 which extends to the first straight leg 62 bent down.

The box plate 12 is angled in the third edge region 54 substantially perpendicular to form a first spring 72. This first spring 72 is inserted into the first receiving groove 58 when the box plate 12 is moved relative to one another relative to the cover plate 14, so that a connection between the box plate 12 and the cover plate 14 is also produced in the third edge region 54. Due to the special shape of the upper groove leg 70, this upper groove leg 70 pushes the first spring against the second envelope 68 and holds it firmly in position.

At a fourth edge portion 74 of box plate 12 and cover plate 14 - here the bottom to be arranged horizontally edge region - a second tongue and groove joint 76 is formed. For this purpose, the cover plate 14 is folded over in the fourth edge region 74 to form a second receiving groove 78.

The second receiving groove 78 is formed on a third envelope 80 on the fourth edge region 74 of the cover plate 14. A lower groove leg 82 is substantially parallel to the third envelope 80 and thus not kinked like the upper groove leg 70 to keep the inserted spring clamped.

The box panel 12 is folded over to form a second spring 84 in the fourth edge region 74 to form a fourth U-profile 86. The fourth U-profile 86 in this case has a spring leg 88, a second straight leg 90 and a fourth web 92 in between. The second straight leg 90 and the spring leg 88 extend substantially parallel, with the spring leg 88 forming the second spring 84.

On the box panel 12, a receiving area 93 is formed by bending, in which a smoke protection seal (not shown) or a soundproofing gasket (not shown) can be inserted.

When moving against each other of the box plate 12 to the cover plate 14, the second spring 84 is inserted into the second receiving groove 78, so that in the fourth edge portion 74, the box plate 12 and the cover plate 14 are firmly connected.

Due to the particular configuration of the first and second rear engagement devices 20, 21 and the two tongue and groove connections 56, 76, the box plate 12 and the cover plate 14 may be arranged in circumferentially arranged door rabbets 94. They are so protected and not visible from the outside. At the same time, the box plate 12 and the cover plate 14 remain mutually displaceable, so that in a manufacturing process, only the edge portions 16, 18, 54, 74 must be folded over and then the box and cover plate 12, 14 are simply connected by moving against each other.

In the Fig. 3 to 11 Individual steps for producing the door leaf 10 are shown.

In a first step, presented in Fig. 3 , the box panel 12 described above is provided with the already formed first rear engagement means 20 on the parallel longitudinal end faces 52, namely the first and second edge areas 16, 18. Furthermore, the second spring 84 is also already formed on a lower end side 96, the fourth edge region 74, and the first spring 72 on an upper end side 98, the third edge region 54. On one of the longitudinal end faces 52 first recesses 100 are provided for lock pockets (not shown). On the opposite longitudinal side face 52 second recesses 102 for bands and securing bolts (not shown) are provided.

In a further step, presented in Fig. 4 , the cover sheet 14 described above is provided. Also, the cover plate 14 is correspondingly provided on the longitudinal end faces 52 with the second rear engagement means 21 and has at the upper end face 98, the first receiving groove 58 and at the lower end face 96, the second receiving groove 78. It also has the first recesses 100 and the second recesses 102 for inserting lock 46 and straps (not shown).

In a third step, shown in Fig. 5 , Reinforcements 104 for the lock pocket, the straps and the securing bolts (not shown) are inserted into the box panel 12. Thereafter, a first adhesive layer 106 according to FIG Fig. 6 applied and according to Fig. 7 an insulating insert 108 forming the door panel 206 is placed in the box panel 12 on the adhesive layer 106. In Fig. 6 the first adhesive layer 106 is merely indicated. As will be explained in more detail below, however, the first adhesive layer 106 is applied only in regions in a predetermined first adhesive pattern 208 so that the box panel 12 and the insulating insert 108 forming the door panel 206 are glued only in regions, in accordance with the first adhesive pattern 208.

In Fig. 8 it is indicated that a second adhesive layer 106a is applied to the insulating insert 108. In Fig. 8 is the second adhesive layer 106a indicated only schematically. As will be explained in more detail below, the second adhesive layer 106a is applied in accordance with a predetermined second adhesive pattern 212 so that the insulating insert 108 forming the door panel 206 is provided with the second adhesive layer 106a only in regions.

The cover plate 14 is applied with its fourth edge region 74 to the third edge region 54 of the box plate 12. The rear gripping devices 20, 21 engage with each other. Along the arrow 48 shown, the cover plate 14 is now moved against the box plate 12.

In Fig. 9 a position is shown in which the cover plate 14 is pushed to a third over the box plate 12. This is readily possible by the formation of the first and second engagement devices 20, 21. The shape of the cross section of the door leaf 10 and the longitudinal section of the door leaf 10 are in Fig. 9 indicated by dashed lines.

The cover plate 14 is in 10 and 11 further along the arrow direction shown on the box plate 12 is moved until it is completely above the box plate 12. In this case, the first and second engagement devices 20, 21 are engaged, as well as the first spring 72 is inserted into the first receiving groove 58 and the second spring 84 in the second receiving groove 78.

In Fig. 10 the situation is shown when the cover plate 14 is almost completely pushed together with the box plate 12.

Fig. 12 shows a longitudinal section through the door leaf 10 in the situation of Fig. 10 ,

The cover plate 14 is almost completely pushed over the box plate 12. The rear gripping means 20, 21 are engaged while, however, the first and second springs 72, 84 are not yet inserted into the first and second receiving grooves 58, 78. If the cover plate 14 is pushed further in the direction of the arrow on the box plate 12, the first and second spring 72, 84 are inserted into the first and second receiving groove 58, 78. The first spring 72 is pressed firmly into the first receiving groove 58 by the bent configuration of the upper groove leg 70.

The described door leaf has the following advantages:

In the method for producing the door leaf 10, only two main steps are necessary, namely first the crimping of the four edge regions 16, 18, 54, 74 on box plate 12 and cover plate 14 and then pushing together box plate 12 and cover plate 14. Further Umfälzschritte after pushing together the two sheets 12, 14 are no longer necessary.

The bonding by means of the adhesive layers 106, 106a increases the rigidity of the door leaf 10, so that it also manages to use as a fire door leaf without additional stiffeners to be introduced separately. In addition leads the surface bonding, distributed over the broad sides, to a high planarity of the metal sheets 200, 202, so that a visually high-quality appearance is achieved.

In order to achieve a high soundproofing value despite the inherently rigid construction without separate additional soundproofing material, it is proposed to provide the adhesive layers 106, 106a not over the entire surface along the entire broad sides, but only in regions in certain adhesive patterns 208, 212. Examples of particularly suitable adhesive patterns 208, 212 are described below with reference to Fig. 13 to 16 explained in more detail.

The Fig. 13 and 14 show a first embodiment of a multifunction door 214 with a frame 216 and the door leaf 10, which is held on door hinges 218, 219 pivotally mounted on the frame 216. It shows Fig. 13 a view of the cover plate 14 of the door leaf, while Fig. 15 a view of the box plate 12 of the door panel 10 shows. With dashed lines is in Fig. 13 a first embodiment of the second adhesive pattern 212 shown; while with dashed lines in Fig. 14 a first embodiment of the first adhesive pattern 208 is shown.

To form the gluing patterns 208, 212, the respective interface between the door panel 206 and the respective metal sheet 200, 202 is divided into a plurality of glued panels 220 and no glued panels 222. The fields with bond 220 and the fields without bond 222 are both in the row direction - in the horizontal direction in Fig. 13 and 14th - In the column direction - in the vertical direction in Fig. 13 and 14 - In each case alternately arranged side by side ordered.

Like a comparison of Fig. 13 and 14 Here, the first bonding pattern 208 and the second bonding pattern 212 are similarly formed as a kind of checkerboard pattern; however, the first and second bonding patterns 208, 212 are different in that the first bonding pattern 208 represents the inverse of the second bonding pattern 212. Seen in plan view of the broad side of the door leaf 10, are thus on the in Fig. 14 shown box side there Fields 220 with bonding present, where on the in Fig. 13 lid shown the fields 222 are present without gluing. As a result, a mutual connection between the respective metal sheet 200, 202 and the door panel 206 is present on both sides.

For example, the broad side of the door leaf 10 is divided in height direction in more than five rows with fields 220, 222 and divided in the width direction in more than three columns with fields 220, 222. The fields have, for example in the height and width direction an extension between 10 cm and 50 cm.

As further in the Fig. 13 and 14 is shown, in the Verklebemustern 208, 212 shown here, the fields 220 glued with adhesive not fully bonded, but have a bond strip 224 on. This bond strip 224 extends substantially through the entire field 220 with bonding. However, in the other dimension, the bond strips 224 are formed smaller than the extent of the field 220.

In the illustrated embodiments, the adhesive strips 224 extend along the direction of displacement during assembly, indicated by the arrow 48. In particular, the adhesive strips 224 extend in the direction of the greatest extent of the door leaf, ie here in the direction of the vertical extension. The ratio of the width of the bond strips to the corresponding width of the field 220 may be between 1:10 to 1: 2 and is preferably about 25%.

In the Fig. 13 and 14 the door leaf 10 is shown in an embodiment where the entire boundary layer between the door panel 208 and the respective metal sheet 200, 202 is divided into the glued panels 220 and the panels 222 without gluing.

Such an embodiment of the door leaf is particularly interesting for a multi-purpose door 214, which is to exercise, for example, smoke protection function and additionally a sound insulation function.

In the FIGS. 15 and 16 a further embodiment of the gluing patterns 208, 212 is indicated, which is optimized for a fire door. Here, only a lower portion of the interface between the door panel and the respective metal sheet in the fields 220, 222 is divided, while an upper portion which extends from the third edge portion 54 in the intended use of the door panel 10 downwards, is glued over the entire surface. This full-surface bonding area 226 extends, for example, over a distance downwards, which is between 3% and 20% of the height extent of the door panel 206, and preferably extends over the entire wide area of the door panel 206.

As a result of this full-surface bonding area 226, the upper area of the door leaf 10 close to the third edge area 54 is made particularly rigid in order to counteract bending of the door leaf 10 in the area of the third edge area 54.

As in the FIGS. 15 and 16 Thus, only a portion of the interface between the door panel 206 and the respective sheet metal 200, 202 can be provided with a mutual, area-wise bonding.

Instead of in the Fig. 13 to 16 Other gluing patterns 208, 212 are also conceivable, preferably the gluing patterns on the one metal sheet 200 are executed inversely to the gluing patterns on the other metal sheet 202.

The Fig. 13 to 16 show thus doors 214 with glued door panels 206. In experiments with full-surface glued door panels in terms of sound insulation function was conspicuous that full-surface glued constructions compared to a conventional steel door structure with box-lid design significantly worse soundproofing achieve. By special gluing patterns 208, 212, for example, checkerboard patterns, or other, in particular periodically repeating patterns, the Soundproofing properties are significantly improved. In order to achieve multifunctional properties, area optimization of the bonding can be carried out in different areas, in particular in peripheral areas or in the area of the head. This is in the FIGS. 15 and 16 illustrated by the example of a full-surface bonding area 226 in the head region of the door leaf 10.

Otherwise shows Fig. 15 the first bonding pattern 208 for bonding the box sheet 12 with the insulating liner 108, while the Fig. 16 2 illustrates the second bonding pattern 212 for bonding the cover sheet 14 to the insulating recess 108. In this embodiment as well, the second adhesive pattern 212-with the exception of the head region or adhesive bonding regions 226 on the third edge region 54 -is embodied inversely to the first adhesive pattern 208.

Preferably, the adhesive is mounted on the cover side offset from the adhesive on the box side.

As adhesive, for example, a one-component polyurethane adhesive comes into consideration. In particular, for fire protection functions, the adhesive may also be mixed with fire protection materials, such as with moisture-emitting materials in case of fire.

LIST OF REFERENCE NUMBERS

10

door leaf

12

box sheet

14

cover sheet

16

first edge area

18

second border area

20

first rear gripping device

21

second rear gripping device

22

box

23

hinge side

24

first U-profile

26

inner thigh

28

outer thigh

30

first jetty

32

cover

34

second U-profile

36

upper leg

38

lower thigh

40

second bridge

42

angling

44

first envelope

46

lock

48

Arrow (shift direction)

50

Catches

52

longitudinal side

53

lock side

54

third edge area

56

first tongue and groove connection

58

first recording groove

60

third U-profile

62

first straight leg

64

receiving arms

66

third jetty

68

second envelope

70

upper groove leg

72

first spring

74

fourth edge area

76

second tongue and groove connection

78

second receiving groove

80

third envelope

82

lower groove leg

84

second spring

86

fourth U-profile

88

spring leg

90

second straight leg

92

fourth bridge

93

reception area

94

door rebate

96

lower front side

98

upper end side

100

first recesses

102

second recesses

104

reinforcements

106

first adhesive layer

106a

second adhesive layer

108

insulating insert

200

first sheet metal

202

second sheet metal

204

cavity

206

door panel

208

first gluing pattern

212

second gluing pattern

214

Multifunctional door

216

frame

218

hinge

219

hinge

220

Fields with bonding

222

Fields without gluing

224

bonding strips

226

bonding area

Claims (15)

A door panel (10) substantially formed of a first metal sheet (200), a second metal sheet (202) defining a cavity (204) therebetween and a door panel (206) in the cavity (204), the door panel (206 ) is bonded to the first metal sheet (200) and the second metal sheet (202),
wherein the first metal sheet (200) is adhesively bonded partially to the door panel (206) with a first bonding pattern (208) formed from bonded surfaces and unglued surfaces, and wherein the second metal sheet (202) is bonded to a second bonding pattern formed from glued surfaces and unglued surfaces ( 212) is partially bonded to the door panel (206). Door leaf according to claim 1,
characterized,
that the first Verklebemuster (208) and the second Verklebemuster (212) are formed differently. Door leaf according to claim 2,
characterized,
that, seen in plan view of a broad side of the door leaf (10), glued surfaces of one gluing pattern (208) overlap non-glued areas of the other gluing pattern (212). Door leaf according to one of the preceding claims,
characterized,
that in a vertical and / or in a horizontal direction over the gluing patterns (208, 212) seen glued and unglued surfaces are arranged alternately side by side. Door leaf according to one of the preceding claims,
characterized,
that in at least one of Verklebemuster (208, 212) bonded and unbonded areas are arranged like a chessboard. Door leaf according to one of the preceding claims,
characterized,
in that at least one edge region (54), in particular on an edge region to be arranged horizontally above, a full-surface bonding between metal sheet (200, 202) and door panel (206) is provided, which covers a larger area than the adhesive bonding within the associated adhesive pattern (208, 212). is trained. Door leaf according to one of the preceding claims,
characterized,
in that the metal sheets (200, 202) are provided at marginal areas (16, 18, 54, 74) with profiles which hook behind one another and are interconnected by a rear hooking of the profilings. Door (214), in particular fire protection door with sound insulation function, characterized by a door leaf (10) according to one of the preceding claims and a frame (216). Manufacturing method for producing a door leaf (10), comprising the steps: Providing a first metal sheet (200) and a second metal sheet (202), wherein the metal sheets (200, 202) are configured to define a cavity (204) therebetween, and Providing a door panel (206) for filling the cavity (204), area-wise bonding of the door panel (206) with a first adhesive pattern (208) with the first metal sheet (200) and partially gluing the door panel (206) to a second gluing pattern (212) with the second metal panel (202). Production method according to claim 9,
characterized,
that the first Verklebemuster (208) and the second Verklebemuster (212) are formed differently. Manufacturing method according to claim 10,
characterized,
that in a plan view of a broad side of the door leaf (10) the first metal sheet (200) is glued at surface areas with the door panel (206), where the door panel (206) and the second metal sheet (202) remain unglued and / or that in plan view seen on a broad side of the door leaf (10), the second metal sheet (202) is glued at surface areas with the door panel (206) where the door panel (206) and the first metal sheet (200) remain unglued. Manufacturing method according to one of claims 9 to 11,
characterized,
in that for connecting the metal sheets (200, 202) and the door panel (206), the respective interface between sheet metal (200, 202) and door panel (206) is divided into glued panels (220) and unadorned panels (222) the glued (220) and non glued (222) fields alternate in both column and row fashion, the glued panels (220) preferably having a gluing strip (224) extending across the panel in one dimension and in the other dimension has a smaller extent than the field with bond (220). Manufacturing method according to one of claims 9 to 12,
characterized,
that the first metal sheet (200) and / or the second metal sheet (202) are glued like a checkerboard to the door panel (206). Manufacturing method according to one of claims 9 to 13,
characterized,
in that at least one of the metal sheets (200, 202) is adhesively bonded to the door panel (206) over at least one edge region (54) of the door leaf (10), in particular on an edge region to be arranged horizontally above. Manufacturing method according to one of claims 9 to 13,
characterized,
in that the metal sheets (200, 202) are provided with rear hooking profiles for mutual rear hooking at edge regions (16, 18, 54, 74), and that the metal sheets (200, 202) are inserted into one of the metal sheets (200) after introduction of the door paneling (206) Application of adhesive according to the respective adhesive pattern (208, 212) are pushed together with behind hook behind hook profiles.

Images