IES20080230A2 - A fireproof door - Google Patents

Abstract

A fireproof door (1) comprises a door panel (3) mounted between frame members formed by upright stiles (13) and horizontal rails extending therebetween. The door panel (3) has an inner layer (17) of intumescent material sandiwched between two decorative outer layers (15,19) of wood. Side edges of the door panel (3) engage in complementary stepped groves (14) in the frame members (13). The groove (14) has a wider outer portion (29) for reception of all three layers (15,17,19) and a narrowed inner portion (28) for reception of a periphery (18) of the intumescent layer (17) which projects outwardly of the decorative outer layers (15,19) and is a push fit in the inner portion (28) of the groove (14) for securing the panel (3) on the frame members. <Figure 2>

Description

The present invention relates to fireproof door comprising a door pahol and a framing member for the door panel. More particularly, the present invention relates to a fireproof door wherein the door panel is mounted in a complementary groove in the framing member.

Fireproof doors are commonly used as part of a Passive Fire Protection (PFP) system for a building. PFP systems aim to slow the passage and spread of fire throughout a building by ensuring that partitions of the building such as doors, walls, floors and their components are capable of maintaining either side of the partition below a critical temperature if a fire breaks out on the other side. Regulations are in place to ensure that buildings meet specific requirements depending on their function and usage. PFP systems are rated by the length of time in minutes that a partition will be able to withstand a fire. Typical fire door ratings include 30 minutes, 60 minutes and 90 minutes.

Components of PFP systems often involve the use of intumescent materials, where the expansion of the intumescent material when it is heated by the fire assists in preserving the structural integrity of the component in which it is contained. Furthermore, many intumescent materials have endothermic properties, allowing them to absorb some of the heat generated by the fire and thus prevent the conduction of the heat through the PFP component.

Fireproof doors can be manufactured in a variety of constructions. If may simply be that the density and thickness of the timber used to construct the door is such that it provides a fire resisting door. Other materials such as Gyproc Fireiine plasterboard or Masterboard can be used with timber facings.

Fireproof doors in a PFP system must meet the same fire safety standards of the wails in which the doors are fitted. This requirement generally implies that the doors will be manufactured from specific fire retardant materials. However, the fireproof doors will also ΙΕΟ 8 0 2 30 -2be required to be aesthetically pleasing as they will be installed In working and living areas. Therefore it is common practice to form such doors having a core of fire retardant materials with a veneer of wood or other aesthetically pleasing surface placed thereon.

A known construction for a “joinery” fire door comprises a rectangular door panel having a layer of intumescent material sandwiched between layers of an outer material such as wood veneer, the door further comprising a pair of stiles mounted on the sides of the door panel and a pair of rails mounted at the top and bottom of the door panel, thus forming a complete door. The door panel is mounted in a groove in the stiles and rails. A bead or similar moulding is placed over the join of the panel and stiles and rails to help secure the panel in place.

As well as the grooves In the stiles and rails in which the panel is mounted and the bead fitted over the join between the components, it is also necessary to pin the panels in position relative to the stiles and rails. This is necessary as, in the case of fire, the bead will be burned off quite quickly, allowing the door panel to shift within the door and consequently compromising the fire safety rating of the door. The addition of the pins to keep the panel in place relative to the stiles and rails ensures that the door will maintain its structural integrity for the required period to ensure the fire safety rating.

The pinning procedure is problematic as it increases the cost, complexity and duration of the manufacturing process. Additionally, the use of pins can negatively affect the appearance of the fireproof door. Timber doors require the holes from pinning to be filled with wood filler, resulting in a less attractive finish. Paper and foil laminates cannot be effectively “touched up”. Therefore it is desirable to be able to manufacture a fireproof door comprising panels and framing members such as stiles and rails that will meet specific fire safety and PFP standards without having to pin the panels of the door in place.

It is an object therefore of the present invention to provide a fireproof door wherein it is not necessary to pin the panel of the door in place. /£0 80 2 30 -3Statements of Invention According to the invention there is provided a fireproof door comprising a door panel and a framing member for the door panel, the door panel being mounted in a complementary groove in the framing member, a composite laminated door panel having at least two layers, namely an inner layer of fireproof material and an outer cover layer bonded to a face of the fireproof layer, a periphery of the fireproof layer extending outwardly of a periphery of the outer cover layer, said groove in the framing member being stepped, the groove having an outer wide portion for reception of both layers of the door panel and an inner narrow portion for reception of the outwardly extending periphery of the fireproof layer, said outwardly extending periphery of the fireproof layer being an interference fit in said inner portion of the groove in the framing member.

In one embodiment of the invention the door panel has three layers comprising an inner fire-proof layer sandwiched between first and second outer layers bonded to front and rear faces of the fireproof layer, the periphery of the fireproof layer extending outwardly of a periphery of each outer layer for engagement within the inner portion of the groove in the framing member, and a periphery of the outer layers engaging within the outer portion of the groove in the framing member.

In a particularly preferred embodiment, the layer of fireproof material comprises an intumescent material.

In this way, the door panel will be held in place relative to the framing member, for example a stile or rail of the door, by the intumescent material, thus negating the need for beading and for pinning the door panel in place. In the case of fire, the intumescent material that protrudes from the door panel and extends further than the layer of outer material will expand within the framing member, effectively locking the door panel in place, ensuring the structural Integrity of the door in the absence of the bead and thereby meeting the fire safety requirements.

In one embodiment of the invention there is provided a fireproof door wherein the layer of fire resistant material extends at least 10 mm and preferably about 15mm further into the framing member than the layers of outer material.

IEO 80 2 30 -4ln another embodiment the door panel extends at least 20 mm and preferably about 25mm into the framing member.

In a further embodiment of the invention there is provided a fireproof door wherein the intumescent material comprises sodium silicate. Sodium silicate is an effective intumescent material.

In one embodiment of the invention there is provided a fireproof door wherein the intumescent material comprises Palusol (Registered Trade Mark (RTM)). Palusol is a particularly effective intumescent material and is particularly suited for use in door panels as it is supplied in a solid sheet form.

In another embodiment of the invention there is provided a fireproof door wherein the outer layers comprise a wood product. Wood products are a desirable outer layer for a door panel because they are versatile, convenient to maintain and install and aesthetically pleasing.

In a further embodiment of the invention there is provided a fireproof door wherein the outer layers comprise High Density Fibreboard (HDF). HDF is particularly suited for use in fireproof doors as it is a hard and dense wood product.

In one embodiment of the invention there is provided a fireproof door wherein the framing member comprises a fire resistant material. In this way, the fire safety rating of the fireproof door may be improved. The fire resistant material may be an intumescent material.

In another embodiment of the invention there is provided a fireproof door wherein the framing member includes a stile of the fireproof door. In this way, the door panel may be secured in place relative to a vertical support member of the fireproof door.

In a further embodiment of the invention there is provided a fireproof door wherein the framing member includes a rail of the fireproof door. In this way, the door panel may be secured in place relative to a horizontal support member of the fireproof door.

HO 8 0 2 3 0 -5In one embodiment of the invention there is provided a fireproof door in which the first outer layer and the second outer layer of the door panel are the same thickness.

In another embodiment the first outer layer and the second outer layer of door panel have different thicknesses. In this way door panels of any desired thickness may be provided to suit particular requirements. Preferably, each outer layer has a thickness of at least 2.8mm.

In another embodiment of the invention there is provided a fireproof door in which the first outer layer comprises a first material and the second outer layer comprises a second material.

In another aspect the invention provides a fireproof door as described herein in combination with a complementary door frame within which the fireproof door is hingedly mounted, an intumescent strip being fitted around an inside face of the door frame for sealing the gap between the door and the door frame in the event of a fire.

Detailed Description of the Invention The invention will now be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings, in which:Fig. 1 is a front elevational view of a fireproof door of the invention; Fig. 2 is a section of the fireproof door along the line A-A in Fig. 1; Fig. 3 is a detail elevational view of a door panel of the fireproof door of the invention; and Fig. 4 is a detail sectional view showing portion of a fireproof door according to a second embodiment of the invention. ΙΕΟ 80 2 30 -6Referring to the drawings, and initially to Fig. 1 thereof, there is shown a fireproof door according to the invention indicated generally by the reference numeral 1, comprising a substantially rectangular upper door panel 3 above a substantially rectangular lower door panel 5 with a lock rail 7 disposed between the two door panels 3, 5. The top of the fireproof door 1 is formed from a top rail 9 situated above the upper door panel 3 while the base of the fireproof door is formed from a bottom rail 11 situated below the lower door panel 5. Sides of the fireproof door 1 are formed from a pair of stiles 13a, 13b which engage the sides of the door panels 3, 5 and the rails 7, 9,11. The stiles 13a, 13b and rails 7, 9,11 effectively form a rectangular framing member for supporting the upper and lower door panels 3, 5.

Referring now to Fig. 2 in particular, there is shown a sectional view along the line A-A in Fig. 1. There is shown the upper door panel 3 comprising a first outer layer 15 and a second outer layer 19 having a layer of intumescent material 17 sandwiched between them. The door panel 3 extends into the stiles 13a, 13b, side edges of the door panel 3 engaging a complementary stepped groove or recess 14 in each stile 13a, 13b. Peripheral side edges 18 of the layer 17 of intumescent material extend outwardly from a periphery 24, 25 of the first and second outer layers 15,19 into narrow inner portions 28 of the grooves 14 in the stiles 13a, 13b. A wide outer portion 29 of the groove 14 receives all three layers 15, 17, 19 of the door panel 3. The periphery 18 of the intumescent layer 17 is a push fit in the inner portion 28 of the groove 14. A similar mounting engagement of a periphery of the panels 3, 5 with the rails 7, 9,11 is provided. The outwardly extending side edges 18 of the intumescent material layer 17 are an interference or push fit into the inner portions 28 of the grooves 14 in the stiles 13a, 13b and rails 7, 9,11.

Fig. 2 also shows portion of a door frame 21 on which the fireproof door 1 is mounted. The door frame 21 has an intumescent strip 23 fitted thereto such that in the event of fire, the gap between the fireproof door 1 and the door frame 21 will be sealed by the expanded intumescent strip 23.

Referring now to Fig. 3 the upper door panel 3 is shown comprising the inner layer of intumescent material 17 which is sandwiched between and protrudes outwardly at each side 18 from a periphery 24 of the first outer layer 15 and the second outer layer 19 (not «0 80 2 30 -7shown in Fig. 3). Preferably, the layer of intumescent material 17 will protrude from the first and second outer layers 15,19 by approximately 15 mm.

Preferably, the door panel 3, 5 will be of a thickness of 10mm while the layer of intumescent material 17 will comprise a layer of Palusol (RTM) having a thickness of 4mm. The outer layers 15,19 each have a thickness of at least 2.8mm.

Fig. 4 shows portion of another fireproof door indicated generally by the reference numeral 30. Parts similar to those described previously are assigned the same reference numerals. In this case a single outer layer 15 is provided on one face of the inner intumescent layer 17. Here again complementary stepped mounting grooves 34 are provided in the frame members 7, 9,11,13 for reception of a periphery of each panel 3, 5. An outer wide portion 35 of the groove 34 receives both the layers 15, 17 and the peripheral edge 18 of the intumescent layer 17 is a push fit in a narrow inner portion 36 of the groove 34.

It will be understood by the person skilled the art that the layer of intumescent material, the first outer layer and the second outer layer may each comprise a plurality of sublayers. For example, the first and second outer layers may comprise a layer of HDF having a thin wooden veneer laminated thereto, or paper/foil laminates.

It will be understood by the person skilled in the art that the fireproof door of the invention may comprise one or more door panels of any shape as long as the edges of the door panels are embedded in a suitably shaped groove in the framing member or members.

In the specification the terms comprise, comprises, comprised and comprising or any variation thereof and the terms include, includes, included or including or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation.

The invention is not limited to the embodiments herein described, but may be varied in both construction and detail within the scope of the appended claims. ΙΕΟ 80 2 30

Claims (5)

1. A fireproof door comprising a door panel and a framing member for the door panel, the door panel being mounted in a complementary groove in the framing member, the door panel comprising a composite laminated door panel having at least two layers, namely an inner layer of fireproof material and an outer cover layer bonded to a face of the fireproof layer, a periphery of the fireproof layer extending outwardly of a periphery of the outer cover layer, said groove in the framing member being stepped having an outer wide portion for reception of both layers of the door panel and an inner narrow portion for reception of the outwardly extending periphery of the fireproof layer, said outwardly extending periphery of the fireproof layer being an interference fit in said inner portion of the groove in the framing member.

2. A fireproof door as claimed in claim 1 wherein the door panel has three layers comprising the inner fireproof layer sandwiched between first and second outer layers bonded to front and rear faces of the fireproof layer, the periphery of the fireproof layer extending outwardly of a periphery of each outer layer for engagement within the inner portion of the groove in the framing member, and a periphery of the outer layers engaging within the outer portion of the groove in the framing member.

3. A fireproof door as claimed in any preceding claim wherein the layer of fireproof material comprises an intumescent material, the intumescent material is Palusol(RTM), the layer of intumescent material extends at least 10 mm further into the framing member than each outer layer in the door panels, and the door panel extends at least 20 mm into the framing member.

4. A fireproof door substantially as hereinbefore described with reference to the accompanying drawings.

5. A fireproof door as claimed in any preceding claim in combination with a complementary door frame within which the fireproof door is hingedly mounted, iEO 80 2 30 -9an intumescent strip being fitted around an inside face of the door frame for sealing the gap between the door and the door frame in the event of a fire. 1/3 ,ΕΟ 80 2 30 Ρ\*>· ΙΕΟ 80 2 30 ΙΕΟ 8Ο 2 30 Fig.3