FIRE RESISTANT SHUTTER DOOR, BUILDING AND FIRE-RESISTANT SLAT FOR A FIRE RESISTANT SHUTTER DOOR

Abstract

 A fire-resistant shutter door comprises a flexible curtain with a resistance to fire for a duration of at least 15 minutes. The curtain comprises a plurality of flexibly linked slats, of which one or more are fire-resistant slats. The fire-resistant slats which comprise a hollow profile (6) made of a composite, fibre-reinforced material. The hollow profile (6) has a hollow inside (7) with of which one or more chambers (8), each defined by a respective chamber wall (9). The chamber wall (9) is at least partially cladded with a fire-protecting material (10) which provides a fire protection to the fibre-reinforced material. Remaining space in the chamber can be filled with additional protecting material (11). The hollow profile can e.g. be manufactured by pultrusion.

Description

Field of the invention

[0001] This invention relates to fire resistant shutter doors, buildings with such doors, fire-resistant slats and curtains for such shutter doors. Although not limited thereto, this invention relates in particular to rolling and overhead shutter doors.

Background of the invention

[0002] Fire resistant shutter doors are known. Such doors consist of a flexible shutter curtain made of a plurality of slats which are hinged together with a flexible link. In mounted condition, the curtain is movably mounted to a guide track with the slats extending with their longitudinal direction substantially perpendicular thereto. The curtain is movable along the guide track, with the flexible link between the slats allowing the shape of the curtain to conform to the path defined by the guide track. When the door is closed, the door will resist for a certain period of time the passage of fire, through the door, from a fire-exposed side to a protected side. More specific, for the specified duration of the fire resistance, flames cannot pass through the curtain from the exposed side to the protected side.

[0003] For example, Metacon of Gouda, the Netherlands, manufactures and sells such fire-resistant doors. The slats of these doors consist of a double walled metal profile which is filled with a mineral wool. Such doors exhibit an excellent fire resistance.

[0004] However, a disadvantage of these doors is that the slats are heavy. Accordingly, the door requires a supporting construction which is sufficiently strong to support the load presented by the shutter doors, and, because of the weight, opening and closing the doors requires relatively powerful motors. Another disadvantage is that manufacturing is complex because each slat has to be assembled from various metal parts.

[0005] Despite various alternative materials and constructions of fire resistant shutter doors having been proposed, such as in British patent application publication GB 2235486, these still have the same disadvantages. For example, the shutter door disclosed in this publication comprises a laminated panel with a load bearing portion of several layers and a fire-resistant portion of other layers. Each portion has covering skins and a core of e.g. balsawood. Manufacturing the complex laminate structure requires a significant number of separate steps to attach the different layers of the laminate. Another disadvantage is that the load bearing portion is still heavy.

[0006] European patent application publication number EP 1 591 614 A2 discloses fire-resistant lamellas for segment gates which consist of a hollow synthetic section of extruded PVC in which is provided a swelling product. The swelling product is a substance which foams when heated, resulting in a considerable volume increase, and which nevertheless remains stiff. This publication discloses that when the temperature rises in case of fire or the like, the swelling product will foam as a result of which the lamella will expand, whereas the swelling product remains stiff. This results, according to this publication, in a broader barrier which is harder to penetrate for a possible fire.

[0007] However, this swelling will affect the physical integrity of the hollow section. The swelling product therefore does not provide a fire protection to the hollow section, and accordingly still risks a breakdown of the hollow section, requiring the stiff swelling product to be designed as a load bearing part that, when the hollow PVC section degrades in case of fire, has to maintain a sufficient physical integrity.

Summary of the invention

[0008] The present invention provides a fire resistant shutter door, a building, a fire-resistant slat and a flexible curtain as described in the accompanying claims.

[0009] Specific embodiments of the invention are set forth in the dependent claims.

[0010] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

Brief description of the drawings

[0011] Further details, aspects and embodiments of the invention will be described, by way of example only, with reference to the drawings. In the drawings, like reference numbers are used to identify like or functionally similar elements. Elements in the FIGs. are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

FIG. 1 schematically shows a perspective view of a first example of an embodiment of a shutter door.

FIG. 2 schematically shows a perspective view of a second example of an embodiment of a shutter door.

FIG. 3 schematically shows a perspective view of a third example of an embodiment of a shutter door.

FIG. 4 schematically shows a perspective view of an example of an embodiment of a hollow profile suitable for the examples of FIGs. 1-2.

FIG. 5 schematically shows a side view of a slat in which the example of FIG. 4 is used.

FIG. 6 schematically shows a perspective view of another example of an embodiment of a hollow profile suitable for the examples of FIGs. 1-2.

FIG. 7 schematically shows a side view of a slat in which the example of FIG. 6 is used.

Figs. 8-12 show side views of an example of a curtain during various stages of an example of the open and/or closing of a shutter door.

Figs. 13 shows a side view of a part of a second example of a curtain.

Figs. 14 shows a side view of a part of a third example of a curtain.

Figs. 15-17 show side views of the third example of a curtain during various stages of an example of the open and/or closing of a shutter door.

FIG. 18 schematically shows a perspective view of a fourth example of an embodiment of a hollow profile suitable for the examples of FIGs. 1-2

FIG. 19 schematically shows a side view of a slat in which the fourth example of FIG. 18 is used.FIG. 20 schematically illustrates a manufacturing line which may be used to manufacture a hollow profile, such as the examples of FIGs. 4 and 6, for instance.

Detailed description of the preferred embodiments

[0012] Because the illustrated embodiments of the present invention may for the most part, be implemented using materials and techniques known to those skilled in the art, details will not be explained in any greater extent than that considered necessary for the understanding and appreciation of the underlying concepts of the present invention and in order not to obfuscate or distract from the teachings of the present invention.

[0013] Referring to FIGs. 1-3, the examples of fire-resistant shutter doors 1 shown therein can, depending on the specific application, for example, meet the requirements of European standard EN 16034:2014. Each of the shown examples comprises a flexible curtain 2 with a resistance to fire for a predetermined duration, for example at least 15 minutes. Depending on the specific implementation and the intended application of the door 1, this period of time may be longer, and the resistance to fire can for example be at least 30 minutes, at least 60 minutes, at least 90 minutes, at least 120 minutes or even 240 minutes or more. The fire resistance duration can e.g. be determined in accordance with EN 16034:2014.

[0014] The curtain 2 comprises a plurality of flexibly linked elongated panels or slats 3. The shown examples of shutter doors are built into a building and allow the opening and closing of a passage e.g. for humans or vehicles, through a wall of the building. Depending on the specific implementation, this may be a wall separating interior spaces of the building, or separating the interior of the building from its exterior. As shown, at opposite longitudinal ends of the slat 3, a guide track 5 is present. The guide track 5 predefines the path along which the curtain 2 is moved when opening and closing the door 1 and guides a movement of the slats 3 when the shutter door 1 is opened or closed. The movement can e.g. be vertical and/or horizontal.

[0015] FIG. 1 shows in this respect a vertical door, and more specific a roller shutter door, where the curtain is movable in vertical direction, as indicated with the arrow. Above the opening to be closed off, the curtain 2 can be wound onto a roll (in this example inside the enclosure 23) when the door is raised and the curtain is moved towards the enclosure 23. The roll will unwind when the door is closed by lowering the curtain 2. When raised or lowered, the movement of the slats 3 is guided by guide tracks 5 which define their path.

[0016] FIG. 2 shows as another example, another vertical door and more specific an overhead door where the curtain is movable in vertical direction as well, but instead of being wound on a roll as in FIG. 1, the curtain 2 is guided by the guide tracks 5 to tilt from a vertical position into a horizontal position and slide in a horizontal direction above and away from the passage when opening. Of course, to close the door 1, the curtain 2 is moved in the opposite direction towards the passage, tilted from the horizontal position to the vertical position and lowered to abut against the wall and close off the passage. In these two examples, the flexible link thus allows the slats to pivot relative to each other.

[0017] In Figs. 1 and 2, the slats 3 are hinged together, but other flexible links are also possible. The link may e.g. in addition or alternatively allow the slats to slide or otherwise perform a lateral movement relative to each other and/or to the guide tracks. FIG. 3 shows for instance, as yet another example, a sliding door. As indicated with the arrow, instead of moving vertically in this example, the door 1 slides horizontally along horizontal guides and the slats 3 are joined in a manner sufficiently flexible to allow the horizontal movement.

[0018] As shown in FIGs 1-3 at the opposite ends 20, 21, e.g. the bottom and/or top of the curtain 2, a special, different panel, hereinafter referred to as a terminating slat 4 may be provided, e.g. which at one longitudinal side is connected to the curtain and at the other, free-end is shaped such that a good, preferably but not necessarily smoke-blocking, closure between e.g. the curtain and the floor (in FIGs. 1 and 2) or wall (in Fig. 3) of the building is obtained. For example, in FIGs. 1 and 2, at the free-end of the terminating slat 4 at the bottom, a sealing strip may be provided which, when the strip touches the floor, seals off the passage between the bottom slat 4 and floor (or in case of a horizontally moving shutter door, between the end of the curtain 2 and the wall).

[0019] Referring now to FIGs. 4-7, the examples of hollow profiles 6 and fire-resistant slats 3 shown therein can be used in a curtain for vertical fire-resistant shutter door, such as shown in FIGs. 1-2. Like the curtain, the fire-resistant slats therein have a resistance to fire for a predetermined duration, for example at least 15 minutes. Depending on the specific implementation and the intended application of the door 1, this period of time may be longer, and the resistance to fire can for example be at least 30 minutes, at least 60 minutes, at least 90 minutes, at least 120 minutes or even 240 minutes or more.

[0020] The shown example of a fire-resistant slat 3 comprises a hollow profile 6 made of a composite, fibre-reinforced material. The hollow profile 6 has a hollow inside 7 with one or more chambers 8 defined by a chamber wall 9. The chamber wall is cladded with a fire-protecting material 10, which provides a fire protection to the fibre-reinforced material. A curtain 2 with fire-resistant slats 3 can be fire-resistant and relatively light at the same time, because the hollow profiles 6 are made of a fibre-reinforced material, while the fire-protecting material in the inside of the hollow profiles 6 provides the fibre-reinforced material of the hollow profile 6 with a protection against fire.

[0021] Fibre-reinforced materials used as load-bearing parts are generally known to provide a very good weight to strength ratio, but up to now were deemed unsuitable for fire-resistant shutter doors. This is because of their limited fire-resisting capabilities, even when the fibre-reinforced matrix contains fire-retardants or fire-resisting filler components. Accordingly, shutter door curtains made of fibre-reinforced materials are, up to now, believed to require a cover of specific fire-resistant layers. These layers are heavy and add complexity, because during normal use they are subject to mechanical wear, e.g. because of friction between moving parts, and are exposed to e.g. impact damage.

[0022] It has now been found that a fire-protecting cladding 10 inside the hollow profile 6 can be sufficient to make a slat fire-resistant and secure the fire-resistance of the curtain 2. Such a cladding can be of a light material because the hollow-profile 6 provides mechanical strength to the slat 3 and bears the loads on the slat. Accordingly the cladding only needs to provide fire-protection. In addition, the cladding 10 can be simple, because it is not part of the mechanical construction and protected by the hollow profile against e.g. mechanical wear or impact damage.

[0023] The resistance to fire provided by the curtain 2 for this duration can relate to different aspects and, e.g., be one or more of the group consisting of: integrity, insulation, radiation and any combination thereof. For example, the combinations may be: integrity and insulation; integrity and radiation; or integrity, insulation and radiation.

[0024] In this respect, the term "integrity" refers to the ability of the curtain 2 to prevent (for the specified duration) upon exposure of one side of the curtain, the fire side 32, the occurrence of flames on the, other, unexposed or fire-protected side 33 of the curtain 2. In addition, this may also be the ability to prevent passage through the curtain 2 of hot gasses. For example, the slats 3 may be non-permeable to gasses and, in addition, be connected such that when the door is closed, smoke and gasses cannot penetrate through the slits or passages between the slats 3.

[0025] The term "insulation" refers to the ability of the curtain 2, when exposed to fire at the fire side 32, to restrict the temperature rise (i.e. an increase relative to the ambient temperature) at the un-exposed side 33 and the temperature rise to remain below a predetermined maximum for the duration of the fire resistance. The maximum can for example be for the average temperature of the non-exposed side, and for example, be a maximum rise of 150°C or less, such as 140°C. In addition or alternatively, the maximum can for example, be the maximum rise for the local or spot temperature, and for example, be 200°C or less, such as 180°C at any one location or spot at the non-exposed side.

[0026] The term 'radiation" refers to the resistance of the curtain 2 to heat radiation, i.e. that the heat radiation measured at the non-exposed side remains under a specific value for a certain period of time upon exposure to fire of the fire-side 32. This reduces the probability of the transmission of fire to the non-exposed side 33 as a result of significant radiated heat. A maximum for the heat radiation of, for example, 15 kW/m² has found provide an effective suppression of this probability for the duration.

[0027] The fire-protecting material can be any material suitable to protect the fibre-reinforced hollow profile 6 in case of fire. The fire-protecting material 10 can, for example, have a heat capacity which is higher than the heat capacity of the fibre-reinforced material and upon exposure to fire of a fire-side of the fire-resistant slat absorb the heat. Thereby the temperature of the hollow profile, or at least the non-exposed side thereof, can be kept below a melting point of the fibre-reinforced material for this duration. This allows to maintain the physical structure sufficiently intact to be fire-resistant for the duration.

[0028] The fire-protecting material can, in addition or alternatively, have a specific thermal resistance which is higher than the fibre-reinforced material. Thereby, the flow of thermal energy from the exposed side to the non-exposed side will be restricted and accordingly at least the parts of the profile, in a flow direction of the thermal energy, downstream of the fire-protecting material will heat-up to a lesser extent. This allows, at least for the duration, the physical structure of the hollow profile to be retained sufficiently intact to be fire-resistant for the duration, even though the parts upstream of the protecting material may exhibit some degradation.

[0029] The fire-protecting material can have a higher auto-ignition temperature than the auto-ignition temperature of the fibre-reinforce material. It has been found that in such a case, where the, in terms of auto-ignition temperature, weaker fibre-reinforced material is at the outside and the stronger material in the chamber, the fire-protecting material can still effectively protect the profile, made of the weaker material, in a manner sufficient to obtain a fire resistance of the curtain for the specified duration.

[0030] The fibre-reinforced material can, for example, have an auto-ignition temperature below 900°C and the fire-protecting material above 900°C. In such a case, the fibre-reinforced material will in a typical fire at the end of the fire-resistance duration exhibit some degradation, but it had been found that the shielding provided by the fire-protecting material to the hollow profile 6 is sufficient to keep the overall structure of the profile 6 intact, and provide the resistance to fire for the duration.

[0031] The auto-ignition temperature of the fire-protecting material can be at least 200°C higher than the auto-ignition temperature of the fibre-reinforced material. It has been found that this is already sufficient for a good protection. Other ranges may be suitable as well such as for example at least 500°C, such as at least 1000°C. These have found to further improve the protection. For instance, the auto-ignition temperature can be at least 1500°C higher than the auto-ignition temperature of the fibre-reinforced material. In such as case, the fire-protection will only in exceptional cases degrade even when the fibre-reinforced material exhibits severe degredation and accordingly provide a very good protection.

[0032] In absolute terms, a suitable auto-ignition temperature of the fire-protecting material can be at least 800°C, for example at least 1000°C, such as at least 1500°C, and most preferably at least 2000°C, although other values may be suitable as well. For example, the fire-protecting material can, for practical purposes, be unflammable and comprise an unflammable carrier material and optionally additional materials. The carrier material can e.g., have a melting point of at least 2000°C, such as at least 3000°C.

[0033] A suitable carrier material has for example found to be MgO, such as MgO based board, for instance of at least 5 mm, such as the boards commercially available from DMS Brandwerende Systemen of the Neltherands under the name "Permoxx" of 6 mm thickness or more. The fire-protecting material can in addition to the carrier material comprise other materials, such as heat-absorbing materials, such as one or more of: Mgel₂, MgCl₂(H₂O), xAl₂O₃.ySiO₂.zH₂O, crude perlite, expanded perlite, glass fibre. The other materials may e.g. contain physically and/or chemically bound H₂O. Such H₂O can e.g. be chemically or physically released after a predetermined period of time shorter than the duration from starting exposure to fire of the fire-side 32, for example when an activation temperature for the release is exceeded in the fire-protecting material due to the exposure. This release will lower the temperature and hence protect the hollow-profile.

[0034] However, other materials may be suitable as well. For example, the cladding material 10 may comprise boards, plates or layers of heat-resistant or isolating materials, or mixtures containing such materials, such as one or more of: hydrous phyllosilicate (e.g. vermiculite board), calcium silicate (such as boards sold by Promat B.V. of Houten, the Netherlands under the brand "Promatect"), aluminium oxides, nesosilicates (like Zircon), gypsum, mineral wool, polyisocyanuraat or thermally isolating, heat resistant hard-foams like polyurethane, just to name a few. In this respect, the cladding may comprise a laminate of, in the fire-propagation direction, a set abutting the chamber wall of one or more initial layers of heat resistant materials, e.g. boards of hydrous phyllosilicate (e.g. vermiculite board), calcium silicate (such as boards sold by Promat B.V. of Houten, the Netherlands under the brand-name "Promatect"), aluminium oxides, nesosilicates (like Zircon). The set of heat resistant material(s) may separate the chamber wall from one or more successive layers of (optionally less-heat resistant) thermally isolating materials, such as hard-foam like polyurethane foam, mineral wool or other isolating material.

[0035] The fibre-reinforced material may be any suitable fibre-reinforced material. For instance, the composite, fibre-reinforced material may comprise a plastic matrix reinforced with, woven or unwoven, fibres. The fibres can e.g. be glass fibres. The plastic matrix can e.g. be a resin matrix, such as one comprising a, cured or uncured, substance selected from the group consisting of: Isophtalic polyester, orthophatalic polyester, vinylester, styrene, and mixtures thereof. The resin matrix may comprise other materials, such as a fire retarding filler, such as aluminium trihydroxide.

[0036] The hollow profile 6 and the slat 3 may be implemented in any manner suitable for the specific implementation. The examples of FIGs. 4-7 are particularly suited for vertical doors where the slats are to be tilted (from a substantially vertical position to a horizontal or vice versa) to e.g. roll the curtain or tilt the curtain. However, it will be apparent that the profiles and slats may be implemented such that they are suitable for horizontal or other doors where the curtain only makes a translational movement. The shown examples, the hollow profile is a rigid, elongated hollow panel with substantially parallel longitudinal sides 32,33 which, when mounted in the door, are parallel to the exposed surfaces of the curtain 2. More specific the sides 32,33 are perpendicular to the guide track 5 and parallel to the direction of movement of the curtain. The hollow profile 6 may be open at the sides facing the guide-track (i.e. perpendicular to the longitudinal sides) and be closed off with a suitable closure when the slat is made with the profile 6. At one or both of those sides 32,33, an attachment suitable to movably mount the slat 3 on the guide track may be attached. The sides 32,33 extend between upper edge 31 and lower edge 30 of the profile, which in mounted position face a respective adjacent slat, except of course for the free-ends of terminating slats. At the upper and lower edge 30,31 the hollow profile is closed in this example.

[0037] As mentioned, the hollow inside 7 is comparted into one (FIGs. 4-5) or more chambers 8 (FIGs. 6-7). Each chamber is defined by a chamber wall of the fibre-reinforced material, which separates the chamber from the exterior thereof. In this example, the chambers extend substantially between the upper and lower edge 30,31 of the profile and separate the fire-exposed side 33 from the protected side 32. Said differently, the chambers are only separated from the exterior by the external walls of the hollow profile. However, in an alternative, for example, between the chambers and the sides 32,33 other elements may be present. In the examples, each chamber has an exposed side wall and a protected side wall which are parallel to the exposed side and the protected side of the profile 6, respectively.

[0038] In the examples, the chamber wall, which separates the chambers 8 and the external surface 12 of the profile 6, is hollow-walled at both the fire-exposed side 32 and the protected side 33 of the profile 6, with an inner wall 14 separated from the outer wall 12 by an interstitial space. This provides additional fire-resistance since in case the outer wall 12 does not resist anymore, the inner wall 14 remains and accordingly, the profile 6 will retain its physical structure sufficiently to block the fire. It will be apparent that this interstitial space may be filled with e.g. fire protecting material as well. In an alternative example, the chamber wall may be hollow-walled at only one of the fire-exposed side 32 and the protected side 33 and be single-walled at the other side, or at both sides.

[0039] As illustrated in FIGs. 4 and 6, the fibre-reinforced material may be exposed at the outside of the hollow profile 6. In the slats 3, this exposed material may be covered or left exposed. In the slats 3 of Figs. 5 and 7, for instance, the exposed material is covered only at the upright, longitudinal side. As shown, this side is covered with a hinge plate 40, which does not provide fire protection for the exposed material. Once the cladding is provided therein, the hollow profile 6 itself is thus as fire resistant as the slat 2.

[0040] The plate 40 can e.g., be a metal plate which does not shield the fibre-reinforced material of the hollow profile 6 against heat and/or fire during the duration. For example, when exposed to fire, the temperature of the plate at both side may increase in the same way, such that it is equal at both sides or at least increases above the melting and/or ignition temperature of the fibre-reinforced material. In this example, the plate 40 only provides a connection between the respective parts of the flexible link at the upper and lower edge of the slat, and may e.g. be perforated or otherwise exposing some of the surface at the fire-exposed side 32 of the slat 3.

[0041] In the shown examples, the hollow profile 6 is a monolithic profile. This allows manufacturing the profile in a simple manner, e.g. using moulding techniques. The hollow profile 6 has a constant cross-section, which allows a simple manufacturing, such as by forcing solid or liquid material through a die of the desired cross-section, like a pultrusion mould.

[0042] FIGs. 5 and 7 show examples of slats 3 comprising the hollow profile of FIGs. 4 and 6 respectively. In the examples of FIGs. 5 and 7, the fire-protecting material is located, seen in a fire-propagation direction, behind the fibre-reinforced material and covers in both examples the chamber wall at the exposed side 32. Said differently, the fire protecting material extends, seen in the fire-propagation direction, in a plane perpendicular to that direction. The fire-protecting material thus shields the parts of the hollow-profile, seen in the fire-propagation direction, behind the cladded wall. The fire protecting material covers the complete exposed-side of the chamber wall and the cladding extends substantially from the lower edge 30 to the upper edge 31 of the hollow profile. In FIG. 5, only the chamber wall at the exposed side is cladded but both the exposed side and the protected side can be cladded with the fire-protecting material 10, as in FIG. 7.

[0043] In the slat 3 of FIG. 5, the chamber is partially filled (with fire-protecting material 10) but in the example of FIG. 7, the chambers 7 are completely filled. In FIG 7 the chamber further comprises a filling material 11 which, completely or partially, fills the remaining chamber space. This can e.g. be a thermally isolating material, such as polyurethane foam, mineral wool or other isolating material. The isolating material enhances the fire resistance and limits the rise in temperature at the protected side, relative to the case in which this isolating material is absent, preferably with at least 50 °C, and more preferrably with several hundreds °C. In a most preferred example, the isolating material limits the rise of the average temperature of the non-exposed side, to 150°C or less, such as 140°C. In addition or alternatively, the rise of the local or spot temperature may be limited to for example 200°C or less, such as 180°C at any one location or spot at the non-exposed side.

[0044] It will be apparent that the thickness of the walls, as well as the length, width and height of the hollow profile 6 may have any suitable value for the specific application. It has been found that even relatively thin, e.g. less than 5mm, such as between 1 and 3 mm, thick walls are already sufficient to be made fire-resistant by the cladding. Tests performed with profiles with such walls and a width of less than 10 cm, e.g. 6 cm or less and more specifically less than 50 mm and a height of less than 20 cm and specifically with a height of about between 13 cm and 16 cm have yielded a good fire resistance, both for massive and hollow walled profiles.

[0045] The slats 3 can be connected to each other with a flexible link that allows the slats to hinge with respect to each other. Although various other types of links are suitable, in the examples of FIGs. 5 and 7, the flexible link closes off the slit or passages between successive slats 3 against smoke and gasses.

[0046] More specific in the examples of FIGs. 5 and 7, adjacent slats in the curtain 2 are pivotally connected together by a two-part hinge. The slats have upper and lower sides or edges 30, 31 which are straight and parallel, and in mounted position of the door are perpendicular to the guide tracks 5. Each hinge has upper and lower elongate hinge members 41, 42; 43, 44, arranged in pairs 41,42;43,44 at the upper and lower edge 30, 31 respectively, with each pair having a hinge member at the fire-exposed side 32 and a hinge member at the protected side 33 of the curtain 2.

[0047] The members 41-44 are pivotally linked together, as shown in more details in FIGs. 8-12. In closed position, the hinge members 41, 44 at the fire-exposed side 32 of a lower slat and of an upper slat, the lower slat being next lower in the series of slats 3 forming the curtain 2, cooperate to restrict passage through, or close-off, the fire-exposed side of the interstitial space 24 between the lower and upper slat, e.g. of and/or against smoke and hot gasses.

[0048] At the protected side 33, the members 42, 43 of the lower slat and the upper slat cooperate to pivot the slats. More specific, the lower hinge member of the upper slat is pivotally attached to the upper member of the lower slat to the upper slat. In the examples, the hinge is formed by curved projections at the upper and lower edge 30, 31 which for directly adjacent slats 3 in the curtain 2 are hooked into each other. More specifically, in FIGs. 5 and 7, each slat 3 has at the fire-exposed side and the protected side a respective hinge plate 40, each of which extends between, and projects beyond, the upper and lower edge 30, 31 of the slat 3. At both edges 30, 31 the plate 40 is terminated by a straight edge which extends parallel to the respective edge 30, 31 and which is curved to form a rim with a curved or hook-shaped cross-section. This rim forms a respective hinge member 41-44. The hinge can thus be obtained in a simple manner, for example by bending a plate, e.g. of a metal and attaching the plate to the longitudinal surface of the hollow profile 6, between the upper and lower edge 30, 31 at the respective side 32, 33.

[0049] As shown, each rim has a hook-shaped transverse cross-sectional outline. At the protected side 32, the upper rim of a lower slat and the lower rim of an upper slat can hook into each other to form a pivot. At the fire-exposed side 33, at least one (or both) of the upper rim of a lower slat and the lower rim of an upper slat abut to the other slat when the slats are pivoted to be parallel to each other. This restricts the passage through the interstitial space 24. In this example, when the door is closed, the rims of the upper slat and of the lower slat at the fire-exposed side 33 lay side-by-side, and abut with their sides. This in addition to blocking off smoke and gas provides a mechanical rigidity to the curtain when the door is closed, Depending on the specific implementation, this passage can be completely closed-off from the fire-exposed side 33. Thus, smoke or hot gasses cannot or only in very limited quantities pass through the curtain 2 to the protected side 32, at least for the duration of the fire-resistance. The smoke-blocking can thus, be obtained in a simple manner, for example by bending a plate, e.g. of a metal and attaching the plate to the longitudinal surface of the hollow profile 6 at the exposed side 33.

[0050] It will be apparent that instead of the shown example, various alternative ways of closing off the passage or slit are possible was well, such as sealing strips or otherwise.

[0051] Referring now to FIGs. 8-12, the slats 3 may be flexibly connected to form a curtain. For example, the example of FIG. 5 can be hooked into another similar, neighbouring slat to obtain the hinge and a pivotable connection between successive slats. FIG. 8 shows a series of slats of a curtain with the shutter door 1 closed. It will be apparent that the terminating slats of the curtain may be different from the shown part of the series, and at their free ends not have hinge members. In this example, the curtain is movable vertically, but it will be apparent that a horizontally movable curtain may likewise be obtained. As shown, at the exposed side, the projection of the hinge plate 40 closes off the passage 24 between adjacent slats 3. This thus blocks, or at least restricts, passage of gasses and/or smoke there between.

[0052] As illustrated in FIG. 9, when the door 1 is opened the curtain 2 is moved, as indicated with the arrow. The slats 3 are moved away from each other because the most upper slat is pulled upwards and this drags the other slats with it. As show, the projections of a slat previously abutting to another slat are no longer in contact with the other slat. The hinging projections at the protected side 33 start touching each other, such that the weight of the lower parts of the curtain is carried by the lower edge hinge member of the directly next upper part. Obviously, when the door is closed, the order is reversed and the hinging projections at the protected side 33 stop touching each because the slats 3 are moved towards each other, until the projections 41, 44 at the other side 32 abut to the respective slat and the weight of the upper slats is thus supported at that side.

[0053] FIGs. 10-12 illustrate the pivoting of the slats. As illustrated, when the slats are guided by the guide track to tilt, e.g. because the upper slat is tilted and moving upwards when opening the door or the lower slat is tilted and moving downwards when closing the door, the hinge allows to drag the other elements of the curtain 2 along with that movement and to guide them along the guide track. As can be seen in FIGs. 11 and 12, the angle between the slats may vary depending on the guide track and the angle between the slats 3 can vary from parallel (180°) to almost straight (e.g. up to 95°). The shown construction thus allows a relatively large degree of movement while effectively blocking the passage of smoke and/or hot gasses between adjacent slats 3. Although other solutions are possible, in this example the large degree of movement is obtained by the hook-shaped hinge members having, seen in cross section, only a contact point which moves along a curved path defined by the other hook shaped member when the slats are tilted.

[0054] FIG. 13 shows a second example of a curtain 2. As shown, in this example the slat 3 has only a hinge plate 40 at the fire-protected side 31 and hence the hollow profile 6 lays exposed at the fire-exposed side 32 and thus is directly exposed to fire. The hollow profile will resist sufficiently though due to the cladding of the chamber. As shown, the plate 40 has hinge members 42,43 which, like the examples of FIGs.8 and 9, can hook into each other to form a pivot joint between the slats 3,3'.

[0055] At the upper and lower edge 30,31 the hollow profile is shaped such that the separation between successive slats 3,3' is closed off by the hollow profiles 6 of a slat 3 and the directly preceding or succeeding slat 3'. This allows a very simple construction that can be manufactured easily. In the present example, the upper and lower edge 30,31 of the profile 6 have conforming shapes, such that the edges 30,31 of successive slats 3,3' touch each other, or leave a very narrow slit, e.g. of less than 1mm such as 0.5 mm or less, when the door is closed. This allows to obtain a good blocking for smoke and gasses, without requiring additional measures after making the hollow profile 6. More specifically, the edges have a curved shape, one of them concave and the other convex. The convex-shaped edge (in this example upper edge 30) can be admitted in the concave edge (in this example the lower edge 31) of another slat. As a result, even if a narrow separation or space 24 remains between the slats 3,3', due to the curvature perpendicular to the air or gas flow entering through the slit-shaped entrance of the space at the fire-exposed side this forms a restriction which at least partially blocks the flow of air or gas entering through the slit-shaped entrance.

[0056] As further shown in FIG. 13, the hollow profile is hollow-walled and both the chamber between the walls, and the interstitial spaces of the hollow-walls themselves are cladded. The slat itself is thus not hollow but massive and constructed of multiple materials. The third example shown in Fig. 14 is substantially the same as the example of FIG. 13 and differs in that the hollow profile 6 of the slat 3 is single-walled and completely filled with fire-protecting cladding.

[0057] FIGs. 15-17 illustrated the pivoting of the slats 3,3' of the curtains in the second and third example. As shown in FIG. 15, initially the door 1 is closed and the conforming edges 30,31 close off the passage between slats 3,3'. In this example, there is a small distance between the edges 30,31 to obtain some tolerance for moving the slats, but the resulting very narrow slit is effectively closed for smoke and gasses for the duration of the fire-resistance, due to the curved shape of the edges 30,31.

[0058] The pivot axis between connected slats is located at the fire-protected side 33, between the lower edge of a slat 3 and the upper edge of the directly adjacent lower slat 3'. Thus, when the curtain is moved, as shown in FIGs. 16 and 17, to open the door, the separation between the edges 30,31 (which have conforming shapes and preferably are separated less than 1mm, such as 0.5 mm or less for example and preferably abut) increases at the fire-exposed side but remains more or less the same at the pivot point when the slats 3,3' are tilted. Contrary to the example of FIGs. 10-12, there are no elements at the fire-exposed side that slide along each other. Accordingly opening the door and tilting the slats requires little force while still a good smoke and gas protection is obtained when the door is closed.

[0059] FIGs. 18 and 19 illustrate a further example of a profile 6 and a slat 3, which differs from the second and third example example as follows.

[0060] The fire-protected side and the fire-exposed side of the upper edge 31 and lower edge 30 are substantially at the same height, whereas in the second and third example there is difference in height between those sides. As shownin FIGs. 18 and 19, the upper edge 31 and lower edge 30 of the profile have complementary shapes. At one of the edges 30,31 the shape is convex (i.e. protruding) and at the other concave (i.e. hollowed inward), such that the profile has at one edge a ridge extending from one side of the profile to the other side of the profile and which projects out of the profile towards the adjacent slat 3'. At the other, opposite end, a slot with a shape in which the ridge fits. The ridge and slot form a restriction against gasses and smoke in the passage formed by the interstitial space 24 over substantially the whole length of the profile 6. Thus, the fire-resistance is enhanced and e.g. the need for special sealing plates at the fire-exposed or protected sides which seal or at least restrict entrance to the passage formed by the interstitial space 24 is obviated.

[0061] Preferably, the ridge has a height which is about at least a quarter, such as at least a third, such as about half of the width of the panel. It is found that this provides an effective blocking of the smoke and gasses.

[0062] In this example the ridge and slot have both a substantially triangular cross-section, which provides a good resistance to the door when closed against loads in a direction from the fire-exposed side to the fire-protected side or vice versa. However, it will be apparent that e.g. a semi-cylindrical ridge and slot or other convex and concave shapes may be used. As shown, the concave and convex parts are located at a distance from the fire-exposed side entrance of the passage.

[0063] In the example of FIGs. 18 and 19, the hollow profile 6 is single walled and has a single chamber 8. The fire-protected side wall of the chamber and the fire-exposed side wall of the chamber are both cladded with a layer of fire protecting material 10, which covers the entire surface of the wall. It is found that despite the profile 6 itself being exposed in case of fire, such a cladding is sufficient to retain the physical integrity of the hollow profile, at least for the specified duration of the fire-resistance. Accordingly, a profile of a very simple shape can be fire-resistance without requiring complex measures.

[0064] The remaining chamber space between the layers 10 is completely filled with a filling material 11, such as a thermally insulating, un-flammable material. Alternatively, In FIG. 7, the filling material 11, completely or partially, fills the remaining chamber space. However, the remaining space can e.g. be partially filled with a solid material or be filled with a gas or a mixture of gasses. The gas or mixture of gasses can be inert. This enhances the fire resistance and avoids, in case of a fire, the gasses reacting with the fibre-reinforced material.

[0065] As illustrated in FIG. 19 with the dashed line profile 3', the hollow profiles can be pivotably connected by a hinge 42,43. In this example the hinge 42,43 is provided at the fire-protected side 33. The hinge can e.g. be door-hinge type with a pin and knuckle which allow leaves attached to the profiles 3 to pivot, but it will be apparent that other types of hinges may be used as well.

[0066] The fire-resistant shutter door, curtain, slats and hollow profile can each be manufactured in any manner suitable for the specific implementation. For instance, as part of manufacturing a door, from a composite, fibre-reinforced material a number of hollow profiles may be manufactured which have a hollow inside with at least one chamber defined by a chamber wall. A number of slats may then be manufactured from the hollow profiles, as part of which the chamber walls may be cladded with a fire-protecting material (which provides a fire protection to the fibre-reinforced material) and the hollow-profiles be flexibly linked together to form a flexible curtain having a resistance to fire for a duration of at least 15 minutes. The manufacturing of the hollow profiles may e.g. use pultrusion and for example comprise pultruding the composite, fibre-reinforced material through a die to obtain a shaped, hollow, material and separating the shaped material into individual hollow profiles.

[0067] FIG. 20 schematically illustrates a manufacturing line 100 suitable for manufacturing hollow profiles. The shown example of a manufacturing line 100 is a pultrusion line and comprises, in a processing direction, spools 102, impregnation tank 104, feeder plates 105, mould or die 106, pulling devices 108 and saw 109. As illustrated, the line 100 further comprise a process controller 107 such a suitably programmed computer or other device that can be operated by a human operator to control the pultrusion process and operate the line 100. The process controller 107 can for example automatically, without human intervention, control the pulling speed, cut off length and various temperatures of the mould.

[0068] The spools 102 are located in racks 101 and on the spools 102 strands of fibre 103 have been coiled.

[0069] The manufacturing line 100 may be used to perform a pultrusion process, which starts with the insertion of the glass fibre reinforcements. At the front of the line 100 the racks 101 containing the spools 102 with the fibre strands 103 are located.

[0070] The fibre strand may have any weight suitable for the specific implementation. Glass fibre has specifically found to be a particularly suitable fibre that provides a very good mechanical strength to the hollow profile. A suitable weight for glass fibre has for example found to be between 5 g/m and 15 g/m such as between 8 and 10 g/m, for example 9.6 g/m. The fibre may, for example, be spun or unspun fibre, provided as strands or woven or unwoven mats or fabrics.

[0071] In the impregnation tank 104, the fibres 103, e.g. strands and/or mats, are coated with a resin. The resin coating can e.g. be a resin base material, which optionally is mixed with a setting agent, dye, flame retarders and other additives. The feeder plates 105 guide the coated fibres to the correct position in the mould 106 and thus ensure a proper coating. The strands of fibre ensure the right level of longitudinal strengthening and the mats provide lateral strengthening. The coating depends on the characteristics required of the profile.

[0072] The resin-coated fibres are subsequently pulled through the mould 106. The mould 106 is heated and has a cross-section which corresponds to (and determines) the cross-sectional shape of the profile 6. In the heated mould, the fibres are shaped into a profile and the profile is, at least partially hardened. As shown, pulling devices 108 grab and pull the fibres and the profile 5 (after the impregnated fibres are shaped into a profile in the mould) through the mould. In the mould 106, the material starts to harden and once it has left the mould 106, the hollow profile 6 is fully hardened and can resist a mechanical load. In this respect, the longitudinal direction of the hollow profile 6 corresponds to the direction in which the profile is pulled through the mould, and accordingly, the hollow profile 6 obtains in this example its final cross-section already in the mould. When leaving the die, the hollow profile 6 does not requires any further processing, other than being cut in the appropriate length, e.g. by the saw 109 or suitable other cutting tool.

[0073] After the hollow profile 6 has been made, the chamber therein may be cladded. For example, strips of suitable length and width of the fire-protecting material may be inserted into the chamber at an open end of the hollow profile, and placed against the walls to be cladded. The material may then be attached, e.g. glued, clamped or otherwise attached to the walls. Thereafter, the open ends can e.g. be closed-off by placing a suitable cap or closure at the respective ends. Of course, if used, other materials may be placed in the chamber 8, which fill the empty space of the chamber 8. For example, mats of mineral wool or other heat insulating materials may be inserted prior to closing the open end(s) of the hollow profile.

[0074] In the foregoing specification, the invention has been described with reference to specific examples of embodiments of the invention. It will, however, be evident that various modifications and changes may be made therein without departing from the broader scope of the invention as set forth in the appended claims and that the claims are not limited to the specific examples shown.

[0075] For example, depending on the specific implementation, the door 1 can close-off a passage between different spaces inside a building or between the interior and the outside of the building. Also, although in the examples of FIGs. 4-7, 18-19 the profile has a constant cross-section, other shapes of the hollow profile are likewise possible.

[0076] In the examples shown, all slats of the curtain 2 are fire-resistant slats 3 but it is also possible to implement only a part of the slats as fire-resistant slats 3 and have one or more of the slats implemented differently. More specifically, in this example, the fire-resistant slats 3 are all similarly shaped and each slat can be connected to a similarly shaped one. However, fire-resistant slats 3 may have different shapes and connection.

[0077] In FIG. 7 and 19, the filling material 11, completely or partially, fills the remaining chamber space. However, alternatively the remaining space can e.g. be filled with a gas or a mixture of gasses. The gas or mixture of gasses can be inert. This enhances the fire resistance and avoids, in case of a fire, the gasses reacting with the fibre-reinforced material.

[0078] Also, the chamber wall 9 can be cladded completely or partially. In the shown examples, only the longitudinal, upright side of the chamber, which extends parallel to the longitudinal direction of the slat 3, is cladded. The fire-protecting material 10 covers the longitudinal side completely but it will be apparent that depending on the specific implementation, the covered side(s) may e.g. be exposed by openings in the material or otherwise locally not be covered by the fire-protecting material 9.

[0079] Furthermore, although the profiles shown in FIG.s 4-7, 18-19 are suitable for vertical doors, it will be apparent that the specific examples of hollow profile and/or slats can be adapted to be alternatively or additionally suitable for horizontal doors, e.g. by a flexible link which allows a limited movement of the slats in the direction of movement of the curtain, but which inhibits tilting of the slats relative to each other.

[0080] However, other modifications, variations and alternatives are also possible. The specifications and drawings are, accordingly, to be regarded in an illustrative rather than in a restrictive sense.

[0081] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word 'comprising' does not exclude the presence of other elements or steps then those listed in a claim. Furthermore, the terms "a" or "an", as used herein, are defined as one or more than one. Also, the use of introductory phrases such as "one or more" and "one or more" in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "at least one" or "one or more" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as "first" and "second" are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.

[0082] Moreover, the terms "front", "back", "top", "bottom", "over", "under" and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is understood that the terms so used are interchangeable under appropriate circumstances, such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

1

shutter door

2

curtain

3

fire-resistant slat

4

terminating slat

5

guide

6

hollow profile

7

profile inside

8

chamber

9

chamber wall

10

cladding of fire protecting material

11

filling material

12

external surface

13

interstitial space

14

inner wall

21

first curtain end

22

second curtain end

23

enclosure

24

interstitial space

30

lower edge

31

upper edge

32

fire-exposed side

33

protected side

40

hinge plate

41

hinge member

42

hinge member

43

hinge member

44

hinge member

100

manufacturing line

101

racks

102

spools

103

fibre strands

104

impregnation tank

105

feeder plates

106

mould

107

process controller

108

pulling device

109

saw

Claims

1. A fire-resistant shutter door, comprising:
a flexible curtain having a resistance to fire for a duration of at least 15 minutes, the curtain comprising a plurality of flexibly linked slats of which at least one is a fire-resistant slat comprising:
a hollow profile made of a composite, fibre-reinforced material, the hollow profile having a hollow inside with at least one chamber defined by a chamber wall, which chamber wall is at least partially cladded with a fire-protecting material which provides a fire protection to the fibre-reinforced material.

2. The fire-resistant shutter door as claimed in claim 1, wherein the fire-protecting material provides a fire protection to the fibre-reinforced material which maintains the physical structure of the hollow profile sufficiently intact to be fire resistant for the duration.

3. The fire-resistant shutter door as claimed in claim 1 or 2, wherein a separation between successive slats is closed off by the hollow profile of a slat and the directly preceding or succeeding slat when the door is closed.

4. The fire-resistant shutter door as claimed in claim 3, wherein the upper and lower edge of the profile have conforming shapes such that the edges of successive slats touch each other or leave a very narrow slit when the door is closed.

5. The fire resistant shutter door of claim 2, wherein adjacent slats in the curtain are hinged together.

6. The fire-resistant shutter door as claimed in any one of the preceding claims, wherein the fibre-reinforced material lies at the outside of the hollow profile.

7. The fire-resistant shutter door as claimed in claim 6, wherein the fibre-reinforced material is exposed.

8. The fire-resistant shutter door as claimed in any one of the preceding claims, wherein the hollow profile is pultruded.

9. The fire-resistant shutter door as claimed in any one of the preceding claims, wherein the fire-protecting material comprises an un-flammable carrier material.

10. The fire-resistant shutter door as claimed in any one of the preceding claims, wherein the hollow-profile provides mechanical strength to the slat and bears the loads on the slat, and the cladding is not part of the mechanical and construction and protected by the hollow profile against e.g. mechanical wear or impact damage.

11. A fire-resistant slat for a fire-resistant shutter door as claimed in any one of claims 1-10.

12. A flexible curtain comprising a plurality of flexibly linked hollows slats as claimed in claim 11

13. A method of manufacturing a fire-resistant shutter door, comprising:

manufacturing from a composite, fibre-reinforced material a number of hollow profiles having a hollow inside with at least one chamber defined by a chamber wall;

manufacturing from the hollow profiles a number of slats, comprising cladding the chamber walls with a fire-protecting material which provides a fire protection to the fibre-reinforced material and flexibly linking the hollow-profiles together to form a flexible curtain having a resistance to fire for a duration of at least 15 minutes.

14. The method of claim 13, wherein the manufacturing of the hollow profiles comprises: pultruding the composite, fibre-reinforced material through a die to obtain a shaped, hollow, material and separating the shaped material into individual hollow profiles.

15. The method of claim 13 or 14, wherein the fire-resistant shutter door is as in any of claims 1-10.

Drawing