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(11) | EP 1 076 753 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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| (54) |
DOOR ARRANGEMENT WITH FIRE PROTECTION FUNCTION TÜRSYSTEM MIT FEUERSCHUTZFUNKTION SYSTEME DE PORTE DOTE D'UNE FONCTION DE PROTECTION CONTRE L'INCENDIE |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
TECHNICAL FIELD
[0001] The present invention relates to a method of manufacturing a door arrangement, particularly a door leaf, a door frame or a dressing of a door, with fire protection function.
PRIOR ART
[0002] A general method in the manufacturing of a fire proof door comprises the cutting of panels made of gypsum or silicate into appropriate dimensions, whereby also openings are made for possible locks or the like. The panels are laid in place and may be fixed against the respective door sheet by an adhesive. An insulation material, e.g. mineral wool, may be applied to the gypsum panels for instance by adhesively securing, whereafter the door leaf is assembled. Each gypsum panel that covers a door sheet is about 6-12 mm thick and contains about 18-20 percent by weight tightly bound water.
[0003] The German patent publication DE 36 03 705 (WOLFGANG ARHEILIGER) relates to a fire protection door with panels and spacers of asbestos-free silicate fibre (also called fibre calcium silicate) with a water content of not more than 10%. The spacers are arranged in pairs in such a way that spaces are formed between these and the panels. The spaces contain air or are filled with some other heat resistant and insulating material.
[0004] The German patent publication DE 38 07 833 (PAUL SCHMITZ GMBH) relates to a sound-insulated steel door containing damping panels on the inside of the door sheets. The panels are of fibre silicate material and have also a fire protecting effect. Mineral wool is applied in the door as a filling material.
[0005] There also exist, as depicted in the European patent application EP 0 741 003 (GRÜNZWEIG+HARTMANN AG), fire protecting viscous silicate masses sandwiched between two glass-fibre textures, which masses are dried at a temperature of 130° Celsius. These fire protecting elements are prefabricated and are then appropriately cut to dimensions adapted for an application and mounted.
[0006] The problems of these known fire protection doors and elements are that it is relatively time-consuming to cut the fire protecting panels and adhesively secure them and thereafter to secure the insulation.
[0007] Besides, they are not flexible to the extent that if an extra strong fire protection is desired locally, this is difficult to achieve. The door leaves also become relatively heavy.
[0008] Furthermore, the silicate masses need a relatively long hardening or drying time. The panels are intermediate stored in this respect at least a few days.
[0009] US-A-4 015 386 describes a method of manufacturing a fire-resistant door wherein the inner surfaces of the door are coated with a lining layer of hydrous alkali metal composition. After evaporation of excess water from the silicate composition, the wall parts are assembled and the casing is filled with a foam resin.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a method in the manufacturing of a door arrangement, particularly a door leaf, a door frame or a dressing of a door, with fire protection function that is effective and flexible.
[0011] Another object of the invention is to provide a fire protecting door arrangement of relatively low weight and to a low cost.
[0012] These and other objects are accomplished according to one aspect of the invention by a method according to which a first and a second door sheet, each door sheet having a first and a second surface, are provided. A fire protecting mainly homogeneous silicate suspension with hardener is applied to at least the first surface of the first door sheet. The silicate suspension ought to comprise a silicate of an alkali metal and a filler, preferably manufactured according to a method where the filler is treated with an acid in a slurry, whereafter this is mixed with an aqueous solution containing a alkali metal silicate. The method is further described in the European patent application EP 0 507 368 (THORS KEMISKE FABRIKKER A/S). A filling complement material, such as for instance the insulation material mineral wool, is applied to said silicate suspension, whereafter the door leaf is assembled, i.e. the first and second door sheets are mounted with the first surface of the respective door sheet facing each other. Finally, the fire protecting mainly homogeneous silicate suspension is allowed to harden and give off part of its loosely bound water.
[0013] The fire protecting mainly homogeneous silicate suspension is preferably applied in a relatively large amount, particularly at least 1-2 kg per square meter door sheet. In this respect it is possible to apply the silicate suspension in a varying amount over the surface to locally vary the fire protecting capability of the door leaf. The silicate suspension may also be applied to the first surface of the second door sheet. Conventional glue may be applied to further increase the adhesion in the door leaf.
[0014] A problem of such an inventive door leaf, particularly in environments with large temperature gradients, may be that the silicate suspension gives off so large amounts of water that the door leaf leaks out water. It is therefore preferable to locate an absorbent means in the door leaf for absorption of the water that is given off from the fire protecting mainly homogeneous silicate suspension. The absorbent means is drying during a very long period of time. Alternatively, or as a complement, the door leaf may be held at a higher temperature during assembly. A preferable temperature is hereby about 50-70° Celsius. The temperature should be high enough to yield a fast evaporation but at the same time low enough to prevent the tightly bound water (that constitutes the real fire protection) to vanish. It is also possible to blow, particularly with compressed air, through the door leaf and hereby remove further water.
[0015] According a second aspect of the invention the above described method is utilized in a corresponding way in the manufacturing of a door frame and a dressing of a door with fire protecting properties.
[0016] The advantages of the present invention comprise a simpler and cheaper manufacturing process and flexibility in placement of the fire protecting material.
[0017] Yet another advantage of the invention is that the mainly homogeneous silicate suspension is non-polluting and allows for a non-polluting manufacturing process. It serves also as a sound-absorbing material.
[0018] Still another advantage is that the door leaf is lighter (about 10-20 kg lighter for a door with a 60 minutes classed fire protection), which implies another, more advantageous, dimensioning of hinges and cheaper transports. The weight of the door leaf is certainly affected by the choice of thickness of the sheet metal and amount of applied silicate suspension.
SHORT DESCRIPTION OF THE DRAWINGS
[0020] The invention is described closer below with reference to Figures 1-3, which are shown only to illustrate the invention and shall therefore in no way limit the same.
PREFERRED EMBODIMENTS
[0024] In the following description, with purposes of explanation and not limitation, specific details are set forth such as particular applications, techniques etc to give clear understanding of the invention. It shall though be clear to the man skilled in the art that the invention may be performed in other ways.
[0025] In Figure 1 an inventive door leaf is shown comprising door sheets 1 made of steel sheet. They may be bent along the sides so that they more easily may be assembled to the finished door leaf.
[0026] A silicate mass or a silicate suspension 2 is mixed with a hardener (accelerator) and is applied to the door sheets 1 through an orifice in relatively large amount, particularly about 10 times more than with conventional gluing, which implies about 1-6 kg for a door leaf in a standard size (about 1-3 kg/m2). Applied amount is related to the fire protection desired and the other parameters of the door. The silicate suspension, which is also referred to as a silicate-based binder, and comprises alkali metal silicate and filler, is object to a separate patent application, see EP 0 507 368. The binder is further described below in this description. The hardener or accelerator, that may contain about 30-60% esters, is applied preferably in small amounts, particularly about 2-5% of the amount of silicate suspension. To achieve a satisfactory fire protection a two-component mass is probably necessary. Examples of products comprising such a silicate suspension and hardener are Thorsil 7104™ and Thorsil K67-P™ manufactured by EKA CHEMICALS.
[0027] The applying is performed in flowing form so that parts of or the complete surface is covered by a couple of millimeters thick layer of silicate suspension. This applying is very flexible and if a better fire protection is desired locally, a thicker layer of suspension is applied there.
[0028] A filling material 3 is then applied, which preferably is constituted by an insulation material such as mineral wool, a spacer or the like, whereafter the door sheets 1 are mounted together to form a door leaf. In this respect the door sheets are screwed or welded together. They may alternatively be mounted on a frame of, for instance, bent or rolled steel sheet. The door sheets may also be integral with each other from the beginning, i.e. constitute part of solely one sheet.
[0029] In this respect cutting out, mounting and gluing of the panels that are described in known art may be despensed with. Fire protection and adhesion may now be obtained at the same time by the same material.
[0030] A fire proof door made of wood may be manufactured according to the invention in a corresponding way. The door sheets are manufactured in wood or in some laminate material and the filling material may be constituted preferably of fibreboard.
[0031] A traditional water glass consists of about 35% of a mixture of Na2O and SiO2, commonly in the relationship 1:3,4, and the rest is water. This implies that such a water glass may give off all its water at room temperature. In practice there remains a lesser part tightly bound water, about 5%, that vanishes first at higher temperatures.
[0032] In the mainly homogeneous silicate suspension utilized in the present invention the portion tightly bound water is approximately 20-25% and the portion free water is of the same size. The rest is dry substance. Tightly bound water means water that vanishes at a higher temperature, particularly at about 100-110°C, and loosely bound (or free) water means water that vanishes during the time at room temperature. The fact that the tightly bound water, which constitutes the main part of the fire protection, vanishes at a temperature of about 70-150°C or around, is essential for its fire protecting capability.
[0033] The silicate suspension may be manufactured according to the following. A filler is treated with an acid in a slurry, whereafter the slurry is mixed with an aqueous solution of an alkali metal silicate to a mainly homogeneous suspension. The acid is preferably an aqueous soluble organic acid. The filler, that ought to be relatively stable in an acid environment and mainly stable in an alkali metal silicate solution, may be constituted of particles of kaolin, feldspar, pearlite, titanium dioxide, aluminium trihydrate, muscovite, talc or the like with a preferable diameter less than about 100 µm. Preferably, the filler is applied in an amount corresponding to 4-80 percent by weight of the alkali metal silicate. The alkali metal silicate is a mixture of M2O, where M is sodium, potassium or a mixture thereof, and SiO2 in a relationship of 1 to about 2-4.
[0034] The suspension manufactured in this manner is constituted by a substantially stable mass that does not stratify. It is highly viscous (about 20000 centipois) and has a relatively good adhesion capability on certain kinds of sheet material, for instance zincified sheet material.
[0035] The silicate suspension described is not as sensitive to moisture as a traditional water glass and it does not give off as much water.
[0036] The silicate suspension is not commonly applied to the upbent edges of the sheets, but it may so be done. Conventional adhesive may also be applied to further increase the adhesion capability. The fire protection agent may furthermore be applied in a door frame and a dressing of a door, see below.
[0037] The loosely bound or free water vanishes commonly during a period of about two years in a mounted door leaf (much faster if the silicate suspension is lying exposed). A further fire protection the two first years may hereby be achieved. However, this implies also problems because of the fact that such large amounts as 1.5-2 kg water vanish. Two solutions to this are proposed.
[0038] The first solution comprises that an absorber means 4 is applied in a door leaf and this absorbs the amount of water given off from the silicate suspension, so that the door leaf does not leak. The absorber means, which preferably is applied in thin light layers, may absorb up to 100-200 times its own weight and dries over very long time.
[0039] The other solution comprises removing of the water (as far as possible) during manufacturing of the door leaf. This is performed by holding the door leaf during mounting at a temperature of 50-70° Celsius, whereby partly the mass hardens faster, partly the free water evaporates.
[0040] By blowing through the insulation by compressed air, large amounts of water may be removed. During experiments half of the water, i.e. 6 dl, has been blown away in about 15 min. The door leaf should, however, not be heated so the first tightly bound water starts to vanish - the fire protection capability of the door leaf is thus reduced.
[0041] Tests in both model scale and full scale have shown that a door leaf according to the present invention pass the so-called EI-fire protection requirements with large margin as regards both temperature rise and integrity. It has also been shown that not more than 25% of the weight of the silicate suspension can vanish at normal room temperature and humidity. Laboratory-aged test elements exhibit very good fire protection properties.
[0042] In the present invention the term door leaf is considered to include also gates and shutters. The door leaf may be a square-edge door or a rabbeted door leaf. Furthermore, the invention is applicable on other parts comprised in a door arrangement. For instance the silicate mass may be applied to a door frame, to its door frame side and/or to its door frame head. The frame may be a single or a double chamfer frame or a special door frame. Furthermore, the silicate suspension may be applied to a dressing of a door.
[0043] The present invention, as hereby described, solves the problems associated with known art by utilizing the principle of using a liquid material, particularly a silicate suspension, for direct application to door sheets, to door frames and to door dressings, for fire protection function or fire protection function and adhesion function. It is obviously not limited to the embodiments described above and shown on the drawings, but may be modified within the scope of the appended claims.
1. Method of manufacturing a door leaf with fire protection function, characterized by the steps of:
- providing a first and a second door sheet (1), each door sheet having a first and a second surface;
- applying adhesive, fire-protecting, substantially homogeneous silicate suspension (2) with hardener to at least the first surface of the first door sheet;
- applying a filling material (3) to said silicate suspension;
- assembling then the first and second door sheets (1) to a door leaf so that the first surface of the respective door sheet is faced toward each other, and
- allowing the fire-protecting, substantially homogeneous silicate suspension (2) finally to harden and give off part of its loosely bound water.
2. Method as claimed in Claim 1, characterized by manufacturing the substantially homogeneous suspension (2) by treating a f iller
with an acid in a slurry, whereafter the slurry is mixed with an aqueous solution
of an alkali metal silicate.
3. Method as claimed in Claim 1 or 2, characterized by applying the fire-protecting, substantially homogeneous silicate suspension (2) also
to the first surface of the second door sheet.
4. Method as claimed in any of Claims 1-3, characterized by applying the fire-protecting, substantially homogeneous silicate suspension (2) in
such a way that parts of or the complete surface is covered by a layer of a thickness
of a. few millimeters.
5. Method as claimed in any of Claims 1-4, characterized by applying the fire-protecting, substantially homogeneous silicate suspension (2) locally
in a varied amount, particularly in a thicker layer, to locally vary the fire-protecting
capability of the door leaf, particularly to increase the fire protection.
6. Method according to any of Claims 1-5, characterized by also applying conventional adhesive to further increase the adhesion in the door
leaf.
7. Method according to any of Claims 1-6, characterized by applying absorber means (4) in the door leaf for absorbing loosely bound water that
is given off from the fire-protecting substantially homogeneous silicate suspension
(2).
8. Method according to any of Claims 1-7, characterized by holding the door leaf during assembly at a temperature of 50-70° Celsius for evaporating
loosely bound water.
9. Method according to any of Claims 1-8, characterized by blowing air, particularly by compressed air, through the door leaf.
10. Method as claimed in any of claims 1-9, wherein said silicate suspension comprises
loosely bound water and tightly bound water, which tightly bound water constitutes
the main part of the fire protection, and the remainder of its loosely bound water
provides for a further fire protection
11. Method as claimed in any of claims 1-10, wherein said first and second door sheets
are made of steel sheet.
12. Method as claimed in any of claims 1-11, wherein said first and second door sheets
are bent along the sides.
13. Method as claimed in any of claims 1-12, wherein said silicate suspension is highly
viscous.
14. Method of manufacturing a door frame or dressing a door with fire protection function,
characterized by applying an adhesive, fire-protecting, substantially homogeneous silicate suspension
with hardener (2) to the door frame or the dressing of a door, applying a filling
material (3) to said silicate suspension and finally allowing the adhesive, substantially
homogeneous silicate suspension to harden and give off part of its loosely bound water.
15. Method according to Claim 14, characterized by manufacturing the substantially homogeneous suspension (2) by treating a filler with
an acid in a slurry, whereafter the slurry is mixed with an aqueous solution of an
alkali metal silicate.
1. Verfahren zur Herstellung eines Türblattes mit Feuerschutzfunktion, gekennzeichnet durch die Schritte:
- Bereitstellung einer ersten und einer zweiten Türlage (1), jede Türlage hat eine erste und eine zweite Oberfläche;
- Auftragen einer klebenden, feuerschützenden, im Wesentlichen homogenen Silikatsuspension (2) mit Härter auf zu mindest die erste Oberfläche der ersten Türlage;
- Auftragen eines Füllmaterials (3) auf die Silikatsuspension;
- Aneinanderfügen der ersten und der zweiten Türlagen (1) zu einem Türblatt, so dass die erste Oberfläche der entsprechenden Türlage der anderen zugewandt ist und
- Erlauben der feuerschützenden, im Wesentlichen homogenen Silikatsuspension (2) abschließend auszuhärten und Teile ihres locker gebundenen Wassers abzugeben.
2. Verfahren nach Anspruch 1, gekennzeichnet durch die Herstellung der im Wesentlichen homogenen Suspension (2) durch Behandlung eines Füllstoffes mit einer Säure in einer Schlämme, wonach die Schlämme
mit einer wässrigen Lösung eines alkalischen Metallsilikates gemischt wird.
3. Verfahren nach Anspruch 1 oder 2, gekennzeichnet durch das Auftragen der feuerschützenden, im Wesentlichen homogenen Silikatsuspension (2)
auch auf die erste Oberfläche der zweiten Türlage.
4. Verfahren nach einem der Ansprüche 1 bis 3, gekennzeichnet durch das Auftragen der feuerschützenden, im Wesentlichen homogenen Silikatsuspension (2)
in einer Art und Weise, dass Teile der oder die komplette Oberfläche mit einer Schicht
mit einer Dichte von wenigen Millimetern bedeckt ist.
5. Verfahren nach einem der Ansprüche 1 bis 4, gekennzeichnet durch das Auftragen der feuerschützenden, im Wesentlichen homogenen Silikatsuspension (2)
örtlich in variierenden Mengen, insbesondere in einer dickeren Schicht, um örtlich
die Feuerschutzfähigkeit des Türblattes zu verändern, insbesondere um den Feuerschutz
zu erhöhen.
6. Verfahren nach einem der Ansprüche 1 bis 5, gekennzeichnet durch das Auftragen eines herkömmlichen Klebstoffs, um die Adhäsion innerhalb des Türblattes
weiter zu erhöhen.
7. Verfahren nach einem der Ansprüche 1 bis 6, gekennzeichnet durch das Anbringen von Absorbiermitteln (4) in das Türblatt, um das locker gebundene Wasser,
welches von der feuerschützenden, im Wesentlichen homogenen Silicatsuspension (2)
abgegeben wird, zu absorbieren.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Türblatt während der Fertigung auf einer Temperatur von 50° bis 70° Celsius gehalten
wird, um locker gebundenes Wasser verdunsten zu lassen.
9. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass Luft, insbesondere Druckluft, durch das Türblatt geblasen wird.
10. Verfahren nach einem der Ansprüche 1 bis 9, wobei die vorgenannte Silikatsuspension
locker- und festgebundenes Wasser enthält und das festgebundene Wasser den Hauptteil
des Feuerschutzes darstellt und der Rest ihres locker gebundenen Wassers einen zusätzlichen
Feuerschutz bereitstellt.
11. Verfahren nach einem der Ansprüche 1 bis 10, wobei die vorgenannten ersten und zweiten
Türlagen aus Stahlblech hergestellt sind.
12. Verfahren nach einem der Ansprüche 1 bis 11, wobei die vorgenannten ersten und zweiten
Türlagen entlang der Seiten gebogen sind.
13. Verfahren nach einem der Ansprüche 1 bis 12, wobei die vorgenannte Silikatsuspension
eine hohe Viskosität aufweist.
14. Verfahren zur Herstellung eines Türrahmens oder einer Türverkleidung mit Feuerschutzfunktion,
gekennzeichnet durch das Aufbringen einer klebenden, feuerschützenden, im Wesentlichen homogenen Silikatsuspension
mit Härter (2) auf den Türrahmen oder die Türverkleidung, Aufbringen eines Füllmateriales
(3) auf die vorgenannte Silikatsuspension und schließlich Aushärten der klebenden,
im Wesentlichen homogenen Silikatsuspension und Abgabe eines Teils ihres locker gebunden
Wassers.
15. Verfahren nach Anspruch 14, gekennzeichnet durch die Herstellung der im Wesentlichen homogenen Suspension (2) durch Behandlung eines Füllstoffes mit einer Säure in einer Schlämme, wonach die Schlämme
mit einer wässrigen Lösung eines alkalischen Metallsilikates gemischt wird.
1. Procédé de fabrication d'un vantail de porte avec une fonction de protection contre
l'incendie caractérisé en ce qu'il comprend les étapes consistant à :
- fournir un premier et un second panneaux de porte (1), chaque panneau de porte ayant une première et une seconde surfaces ;
- appliquer une suspension de silicate adhésive, ignifuge et substantiellement homogène (2) avec un durcisseur sur au moins la première surface du premier panneau de porte ;
- appliquer un matériau de remplissage (3) à ladite suspension de silicate ;
- assembler ensuite les premier et second panneaux de porte (1) en un vantail de porte de façon à ce que les premières surfaces des panneaux de porte respectifs se font face l'une à l'autre, et
- laisser enfin la suspension de silicate (2) ignifuge et substantiellement homogène durcir et évacuer une partie de son eau faiblement liée.
2. Procédé tel que revendiqué dans la revendication 1, caractérisé en ce que la suspension (2) substantiellement homogène est fabriquée en traitant une charge
avec un acide dans une boue, la boue étant ensuite mélangée avec une solution aqueuse
de silicate de métal alcalin.
3. Procédé tel que revendiqué dans la revendication 1 ou 2, caractérisé en ce qu'une suspension de silicate (2) ignifuge et substantiellement homogène est également
appliquée à la première surface du second panneau de porte.
4. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 3, caractérisé en ce que la suspension de silicate (2) ignifuge et substantiellement homogène est appliquée
de manière à ce que des parties ou la totalité de la surface soi(ent) couverte(s)
par une couche de quelques millimètres d'épaisseur.
5. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 4, caractérisé en ce que la suspension de silicate (2) ignifuge et substantiellement homogène est appliquée
localement en une quantité variée, notamment en une couche plus épaisse pour faire
varier localement la capacité de protection contre l'incendie du vantail de porte,
particulièrement pour augmenter la protection contre l'incendie.
6. Procédé selon l'une quelconque des revendications 1 à 5, caractérisé en ce que de l'adhésif conventionnel est en outre appliqué pour accroître l'adhérence dans
le vantail de porte.
7. Procédé selon l'une quelconque des revendications 1 à 6, caractérisé en ce que des moyens formant absorbeur (4) sont appliqués dans le vantail de porte pour absorber
l'eau faiblement liée qui s'échappe de la suspension de silicate (2) ignifuge et substantiellement
homogène.
8. Procédé selon l'une quelconque des revendications 1 à 7, caractérisé en ce que le vantail de porte est maintenu durant l'assemblage à une température de 50-70°C
pour faire évaporer l'eau faiblement liée.
9. Procédé selon l'une quelconque des revendications 1 à 8, caractérisé en ce que de l'air est soufflé, particulièrement de l'air compressé, à travers le vantail de
porte.
10. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 9, dans lequel
ladite suspension de silicate comprend de l'eau faiblement liée et de l'eau fortement
liée, l'eau fortement liée constituant la partie principale de la protection contre
l'incendie et le reste de son eau faiblement liée fournissant une protection supplémentaire
contre l'incendie.
11. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 10, dans lequel
lesdits premier et second panneaux de porte sont fabriqués dans une feuille de métal.
12. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 11, dans lequel
lesdits premier et second panneaux de porte sont coudés sur les côtés.
13. Procédé tel que revendiqué dans l'une quelconque des revendications 1 à 12, dans lequel
ladite suspension de silicate a une viscosité élevée.
14. Procédé de fabrication d'un cadre de porte ou de l'habillage d'une porte avec une
fonction de protection contre l'incendie, caractérisé en ce qu'une suspension de silicate (2) adhésive, ignifuge et substantiellement homogène avec
un durcisseur (2) est appliquée au cadre de la porte ou à l'habillage de la porte,
un matériau de remplissage (3) est appliqué à ladite suspension de silicate et la
suspension de silicate adhésive, ignifuge et substantiellement homogène durcit et
évacue une partie de son eau faiblement liée.
15. Procédé selon la revendication 14, caractérisée en ce que la suspension (2) substantiellement homogène est fabriquée en traitant une charge
avec un acide dans une boue, la boue étant ensuite mélangée avec une solution aqueuse
d'un silicate de métal alcalin.