Fire rated door with a surrounding door frame

A fire rated door with a surrounding door frame, consisting of a glass pane, which is embedded between its circumferential metal frame, said fire rated door consists of at least one door leaf realized from two glass panes spaced apart by means of profiles, whereby the glass panes extend almost as far as to the border of the door leaf and a transparent fire protection material is included between the spaced glass panes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a fire rated door with a surrounding door frame, comprising a glass pane, which is embedded within its circumferential metal frame. In this application, inter alia, two glass panes are proposed for a fire rated door including a frame spacing apart the glass panes.

2. Background of the Invention

Today, fire rated doors are frequently executed as metal doors, the reason for said execution type are cost reduction effects.

Such fire rated door is for example disclosed by European Patent No.: 0 401 550 A2, where a glass pane is mounted within a metal frame equipped with a circumferential groove. In this case, the glass pane ends before the frame and is connected with tile metal frame by means of additional metal edge strips serving as compensating adapters. In this case, the metal strips are connected with traditional fire rated glue, for example made on water-glass base.

A door frame profile for fire rated doors is disclosed by European Patent No.: 0 444 393 A2, where a glass pane is retained in a strong door frame profile. The door frame profile is executed as hollow section and it presents, inserted into its chambers, fire rated plates that guarantee the fire resistance of such a door.

A fire-resistant glazing is described in German Patent No.: 296 45 259 A1. In this case, silicate glass panes made from tempered glass are used on the one side, and, on the other side of an intermediate air gap, a reinforced silicate glass pane is used. The construction of such fire-resistant glazing is realized by means of a metal frame embracing and overlapping the border edge.

German Patent No.: 297 42 665 A1 reveals a fire retarding swing door or center pivoted door, where the door frame respectively the borders of the door leaves present a thermal insulative material, extending over the entire length respectively the entire width. This thermal insulative material will expand when heat develops, such that in the event of a fire, the door component includes a secure fire barrier. This door is composed of plane material, which is not transparent and, in a partial region, is interrupted by a window to be mounted.

OBJECT OF THE INVENTION

As the above state-of-the-art shows, such technical designs today no longer match contemporary architecture. Today's goal is to give the impression that de-materialized transparent structures are used, which can no longer be achieved with the constructions known from the state-of-the-art and it is therefore the object of the invention to propose a solution realizing the conception under economical aspects likewise of the region of the required fire protection partitions with its passageways, such that the observer does not notice that the present zone is actually a fire protection partition including a fire rated door. Simultaneously the solution of this task should include at the same time an increased safety feature aspect.

SUMMARY OF THE INVENTION

The present invention teaches that this object can be accomplished in that the fire rated door consists of at least one door leaf built from two glass panes spaced apart by means of profiles, said glass panes almost extending as far as to the border of the door leaf.

The dependent claims represent a further embodiment of the inventive idea.

It is proposed to conceive a fire rated door according to the principle of “structural glazing” such that the door leaf consists of spaced plane glass panes. The glass panes are spaced apart by means of an intermediate frame made from profiles. In this case, the glass panes extend as far as almost to the border of the door leaf, only the proper edges are protected from damage by a small overhang of the intermediate profiles. As this protection applies just to the edges, the whole area of the spaced glass panes is—free froze any other material. In this case, a transparent fire protection medium is included between the spaced-glass panes. For example a fire rated gel or any other suitable transparent fire protection medium can be used as fire protection medium. Depending on the fire rating class, it is however also possible to abandon the fire protection medium. Furthermore according to the inventive idea, it is possible to include, between both spaced exterior glass panes by means of corresponding spacers, a fire protection glass pane of the known type. To make the frame profiles, which are placed between the glass panes, invisible, the glass panes are provided with an enameling on the interior side in the region where the profiles are placed. By doing so, the aspect of increased safety is respected, and the complete fire rated door is realized as transparent construction unit. Simultaneously, due to the fact that no profiles are visible, the complete appearance of said architectural structures as “structural glazing” is realized.

The profiles are preferably executed as solid profiles and can be manufactured from metal, plastic, steel or wood. In case of a fire rated door in plastic execution, a glass fiber reinforced plastic is preferably used. This plastic is composed such that endless glass fiber rovings oriented in axial direction are used in the plastic profiles. Simultaneously in radial direction, the profiles are reinforced with a glass fiber complex. These glass fibers are impregnated with a resin matrix and hardened within a heated mold. The resin matrix moreover includes fire-retarding fillers. Simultaneously appropriate fittings are incorporated within the profiles, likewise at the same time invisible for the observer. In order such door corresponds to fire protection requirements, so-called fire protection laminates in form of tapes are either incorporated into the profiles or they are also included within the door frame surrounding the fire rated door. Therefore, in the event of a fire, under the effect of heat development, the tapes will intumesce, which action simultaneously guarantees a tight barrier with regard to the source of the fire. According to the invention, such fire rated door is suitable for retrofitting. For this purpose, an existing jamb will be capped with corresponding fire resisting material, for example with gypsum plasterboards or likewise with corresponding additional profiles, which are executed such that two identical profiles are placed against each other over an existing jamb, and they are interconnected by means of an appropriate element, which may act at the same time as a fire protection laminate.

Such designed fire rated doors can also be executed as skylight above the door frame, and likewise as fixed side panels. Such execution of complete fire rated walls addresses the idea to create a de-materialized fire rated wall.

The proposed fire rated door can be manufactured as single action door (swing door) with a rebate, or as center-pivoted door. Besides the execution with a single leaf, likewise a double leaf execution with an inactive and an active leaf is possible.

In case of an execution as single action door, one of the two spaced glass panes is larger than the other one, and a connection between them is guaranteed by means of a gradual profile.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1illustrates in a front view a fire rated door with a door leaf2and with a door frame31surrounding the door leaf. Reference numeral3identifies an enameling on the glass panes4and5stretching alongside the edges of the door leaf2. A vertical section of a single leaf door according toFIG. 1is represented in FIG.2. As here it is only question of the fire rated door's technical structure, all non-relevant parts have been omitted.

The door leaf2is composed as structural glazing, that means the door leaf2includes two glass panes4and5, they are building quasi the entire door leaf. In the upper part, the glass panes4and5are spaced apart by means of a profile6and in the lower part, close to a floor24, they are spaced apart by means of a profile7. As it is evident from the illustration inFIG. 2, the glass panes4and5extend with their glass, pane edges10over the entire height and thus over the entire width of the door leaf2, and they are simultaneously secured by means of profile projections11provided at the profile6, and by means of profile projections28provided at the profile7. Therefore, in this embodiment example, the glass pane edges10are provided with a small chamfer, which is covered at the same time by profile lips. These provide an optimum protection, especially in the region of the edges, for the glass panes4and5, which are preferably manufactured from safety glass (single layer safety glass, ESG). The profile6is executed as solid profile and is, likewise the profile7, preferably manufactured from light metal, plastic or wood or from any other appropriate material. In this case, the profile6presents in its exterior closing region an exterior edge14with a rounded (ball-shaped) form. On the air gap30side, between the glass panes4and5, the profile6is executed with a deepening12arranged between projections13on either side, which provide a locating for the glass panes4and5and thus for the connection of the glass panes4and5with the profile6.

Oriented towards the space between the glass panes4and5, the profile7has got the same cross section as the profile6. However, in the exterior region of the door leaf2in further continuation of the profile projection28, legs15are conformed pointing towards the floor24. In their center, the legs15include a deepening16. The deepening16is provided to mount for example door rails to connected a door closer or to connect other fittings. The legs15are provided to adapt the prefabricated fire rated door on site to the required dimension. By correspondingly cutting the legs15, the optimum length will be achieved for such fire rated door type without dismounting the door leaf on site.

An enameling3is provided on the glass panes4and5, in the connection region between the profiles7and6, whereby said profiles6also run vertically. By doing so, it is guaranteed that the profiles6and7, installed within the air gap30, are not visible to the exterior side. As only the exterior edge zone is concerned, despite the enameling3, the entire door leaf's2appearance is not damaged in a completely de-materialized wall manufactured only from glass, as frame parts and moreover fittings are invisible. Simultaneously it is guaranteed that the glass panes4and5are not executed with boreholes, to ensure an increased fire protection.

The air gap30is partially filled by a fire rated glass pane9. The fire rated glass pane9is supported by means of spacers8, leaning on the glass panes4and5. The ends of the fire rated glass pane9engage in this case into the deepenings12, such that if the fire rated glass pane respectively the profiles6and7expand, a destruction of the fire rated glass pane9will not occur.

The upper part ofFIG. 2illustrates a door frame31, which is mounted on an existing jamb identified by numeral18and which is installed within mortar23over masonry17. In this case, the door frame31is realized from two almost L-shaped additional profiles19. On the one hand, at the mortar23, a sealing21seals the profile19, whereby in the center region of the door leaf2, a gap remains between the additional profiles19. This gap is closed by means of a fire protection laminate in form of a sealing profile22. The additional profile19is simultaneously sealed and fastened in this zone with regard to the existing jamb18by means of a sealing20. In the event of a fire, an automatic sealing of the door frame31with regard to the door leaf2would be achieved thanks to the intumescence of the fire protection laminate22.

In another embodiment example, inFIG. 3, the fire protection effect of the door leaf2is realized in another way. Instead of proceeding like in FIG.2and using a fire rated glass pane9, in this case a fire protection material26is employed, which is preferably transparent and liquid. To introduce the fire protection material26into the door leaf, spacer sections25are incorporated with a certain distance29into the air gap30, whereby they immerse simultaneously into the deepenings12. As shown inFIG. 3, the spacer section25is executed as double-wall spacer section in order to compensate corresponding expansion coefficients of the fire rated material26. The structure of this door, and likewise of the one displayed inFIG. 2, clearly reveals that the observer does not recognize this door-type, constructed according to the principle of dematerialized door leafs, from the outside as a fire rated door and that nevertheless, in the event of a fire this door type guarantees sufficient and corresponding protection within a fire protection partition.

Due to the fact, that the deepening12situated within the frame is provided in the profiles6and7, an increased safety potential is given, as in the event of a fire, for example the fire protection material represented inFIG. 3will stiffen and will persist as plane material, thanks to the profiles6,7blocked on the exterior side in the door frame31, even if one or the two glass panes4,5should burst. This is likewise applicable to the fire protection glass pane9of FIG.2.

A center-pivoted door, which can be realized without any problem for example from profiles6in conjunction with a fire rated glass pane9, is illustrated in FIG.4. In a horizontal section, the center-pivoted door32is arranged inside the additional profiles19of the door frame31. Here again, it is evident that in the event of an outbreak of fire and an increase in temperature the sealing profile22seals the center-pivoted door32with regard to the door frame31.

In an application where the center pivoted door32is installed inside an appropriate fire resistant jamb18, sealing profiles1, in form of fire protection laminates, are incorporated into the exterior edges14of the profiles6oriented towards the jamb18.

FIG. 6represents a double leaf center-pivoted door32including two leaves, located between a door frame made from gypsum plasterboards27mounted on a sub-structure33in this case again, the center-pivoted doors32are executed with sealing profiles1in the zone of the door frame as well as in the central region.FIG. 7illustrates an example analogous toFIG. 6, whereby in this case fire protection laminates are only included in the central region in the profiles6and in the region of the capped jamb18between the additional profiles19, the sealing profile22provides properly sealing in the event of a fire.

The description clearly reveals that said designed fire rated door is absolutely conform to its final purpose and simultaneously provides a free view which is usually not the case with a fire rated door made from steel or sheet metal.

One feature of the invention resides broadly in a fire rated door with a surrounding door frame, consisting of a glass pane, which is embedded within its circumferential metal frame, characterized in that the fire rated door consists of at least one door leaf (2,32) built from two glass panes (4,5) spaced apart by means of profiles (6,7), said mass panes (4,5) almost extend as far as to the border of the door leaf (2,32).

Another feature of the invention resides broadly in a fire rated door characterized in that a transparent fire protection material (9,26) is comprised between the spaced glass panes (4,5).

Yet another feature of the invention resides broadly in a fire rated door characterized in that the profile (6) presents a rounded exterior edge (14) continuing on either side respectively in a profile projection (11), which are respectively executed such that just the glass pane edges (10) (thickness of the glass panes4,5) of the glass panes (4,5) are covered.

Still another feature of the invention resides broadly in a fire rated door characterized in that the profile (7) is arranged in the horizontal lower part of the door leaf (2,32), and respectively presents two recesses (28) having almost the dimension measure of the thickness of the glass panes (475), into which recesses the glass panes (4,5) are embedded, and deflecting legs (15) with intermediate groove (deepening) (16) are realized underside.

A, further feature of the invention resides broadly in a fire rated door characterized in that the profiles (6,7) present a groove (deepening) (12) oriented towards an air gap (30) between the glass panes (4,5).

Another feature of the invention resides broadly in a fire rated door characterized in that the fire protection material is a fire rated glass pane (9) and inserted into the grooves (deepenings) (12), said fire rated glass pane (9) is supported by spacers (8) with regard to the lateral glass panes (4,5).

Yet another feature of the invention resides broadly in a fire rated door characterized in that a circumferential spacer section (25) engages into the groove (deepening) (12), leaning at the same time on the glass panes (4,5) and a space created by means of the spacer section (25) is filled in with a fire protection material (26).

Still another feature of the invention resides broadly in a fire rated door characterized in that the fire protection material (26) is a fire rated gel.

A further feature of the invention resides broadly in a fire rated door characterized in that the spacer section (25) is installed at a distance (29) with regard to the profiles (6,7).

Another feature of the invention resides broadly in a fire rated door characterized in that the spacer section (25) is executed as double wall with intermediate air gap.

Yet another feature of the invention resides broadly in a fire rated door characterized in that a circumferential frame is realized between the glass panes (4,5) by means of the profiles (6,7), which frame is covered through an enameling (3) on the glass panes in the region of the profiles (6,7).

Still another feature of the invention resides broadly in a fire rated door characterized in that the profiles (6,7) are made from plastic, metal, steel or wood.

A further feature of the invention resides broadly in a fire rated door characterized in that fittings are incorporated within the profiles (6,7).

Another feature of the invention resides broadly in a fire rated door characterized in that a fire protection laminate (1,22) is installed into the exterior edge (14) of the profiles (6,7), which laminate will intumesce when heat develops.

Yet another feature of the invention resides broadly in a fire rated door characterized in that the door frame consists of a divided additional profile (19) with intermediate fire protection laminate (22).

Still another feature of the invention resides broadly in a fire rated door characterized in that the door frame is mounted over an existing jamb (18).

A further feature of the invention resides broadly in a fire rated door characterized in that the door frame is built by gypsum plasterboard (27).

Another feature of the invention resides broadly in a fire rated door characterized in that the door leaf (2) is a single leaf or a double leaf swing door.

Yet another feature of the invention resides broadly in a fire rated door characterized in that the door leaf (2) is a single leaf or a double leaf center pivoted door (32).

Still another feature of the invention resides broadly in a fire rated door characterized in that the glass panes (4,5) consist of safety glass.

A further feature of the invention resides broadly in a fire rated door characterized in that the fire rated door's fire protection efficacy is achieved by means of the fire protection laminate (1,22) introduced into the profiles (6,7) respectively between the additional profiles (19).

Another feature of the invention resides broadly in a fire rated door characterized in that the plastic is a glass fiber reinforced plastic.

The components disclosed in the various publications, disclosed or incorporated by reference herein, may be used in the embodiments of the present invention, as well as equivalents thereof.

All of the patents, patent applications or patent publications, which were cited in the PCT Search Report dated Oct. 29, 2000, and/or cited elsewhere are hereby incorporated by reference as if set forth in their entirety herein as follows:

The corresponding foreign and international patent publication applications, namely, Federal Republic of Germany Patent Application No. 199 33 406.4, filed on Jul. 21, 1999, having inventor Walter Degelsegger, and International Application No. PCT/EP00/06886, filed on Jul. 19, 2000, having inventor Walter DEGELSEGGER, as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein.

U.S. Pat. No. 6,668,499, issued on Dec. 30, 2003, having the inventor Walter DEGELSEGGER, and claiming priority from Federal Republic of Germany Patent Application No. 199 33 410.2, which was filed on Jul. 21, 1999 and International Patent Application PCT/EP00/06884, which was filed on Jul. 19, 2000 as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein.

U.S. Pat. No. 6,421,968, issued on Jul. 23, 2002, having the inventor Walter DEGELSEGGER, and claiming priority from Federal Republic of Germany Patent Application No. 199 33 400.5, which was filed on Jul. 21, 1999 and International Patent Application PCT/EP00/06888, which was filed on Jul. 19, 2000 as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorporated by reference as set forth in their entirety herein.

U.S. Pat. No. 6,606,831, issued on Aug. 19, 2003, having the inventor Walter DEGELSEGGER, and claiming priority from Federal Republic of Germany Patent Application No. 199 33 408.0, which was filed on Jul. 21, 1999 and International Patent Application PCT/EP00/06893, which was filed on Jul. 19, 2000 as well as their published equivalents, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references cited in any of the documents cited herein, are hereby incorproated by reference as set forth in their entirety herein.

The above-described figures are again referred to:

FIG. 1shows a view of a single leaf fire rated door, as seen from the front.

FIG. 2shows a vertical section through a fire rated door according toFIG. 1, as seen in a profile front the side, with the floor (24) in the bottom of the drawing, and the door frame (31) at the top of the drawing. The door is shown with a fire rated glass pane (9) between two glass panes (4,5). Further the door is shown with a groove (deepening) (16) surrounded by two legs (15) toward the floor (24).

FIG. 3shows a fire-rated door in a vertical section according toFIG. 1, as seen in a profile from the side, with the floor (24) in the bottom of the drawing, and the door frame (31) at the top of the drawing. The door is shown with a fire protection material (26) between two glass panes (4,5). Further the door is shown with a groove (deepening) (16) surrounded by two legs (15) toward the floor (24). The door frame (31) preferably consists of additional profiles (19) covering the original jamb (18) on each side.

FIG. 4shows a fire rated door according toFIG. 1represented as a horizontal section with a capped jamb, as given in an overhead view, with the door frame (31) on each side of the center pivoted door (32). The door is shown with a fire rated glass pane (9) between two glass panes (4,5).

FIG. 5shows likeFIG. 1, as horizontal section with an existing door frame, as given in an overhead view, with the jambs (18) on each side of the center pivoted door (32). The door is shown with a fire rated glass pane (9) between two glass panes (4,5).

FIG. 6shows a horizontal section through a double leaf center pivoted door system where the door frame is executed with fire rated plates, as given in an overhead view, with the gypsum plasterboard door frame (27) on each side of the double leaf center-pivoted door (32).

FIG. 7shows a Horizontal section through a double leaf center-pivoted door with a capped frame, as given in an overhead view, with the capped jamb (18) on each side of the double leaf center-pivoted door (32).

FIG. 1broadly illustrates a front view of a single leaf fire-rated door (2) with a door frame (31) surrounding the door leaf (2). Reference numeral (3) identifies an enameling on the glass panes (4and5) (seeFIGS. 2,3,4,5,6and7) stretching alongside all the four edges of the door leaf (2). The technical structures of the door and variations hereof are broadly being described inFIGS. 2,3,4,5,6and7.

FIG. 2broadly illustrates a vertical section of a single leaf fire-rated door as seen in a profile from the side, with the floor (24) in the bottom of the drawing and the door frame (31) in the top of the drawling. The door leaf (2) is broadly composed by two glass panes (4and5) spaced apart in the upper part by means of a profile (6) and in the lower part (close to the floor (24) by means of a profile (7). The glass panes (4and5) which are provided with a small chamfer at the glass pane edge (10) extend possibly quasi over the entire height and over the entire width of the door leaf (2). The profiles (6and7) are broadly made with small profile projection (11and28) which possibly cover the extreme edge (10) of the glass panes (4and5) by profile lips. Simultaneously, the glass panes (4and5) are maybe secured by the profiles (6and7). The lips possibly provide protection in the region of the edges of the glass panes (4and5) which are preferably manufactured from safety glass (single layer safety glass, ESG).

The profiles (6and7) are both preferably executed with projections (13) which provide grooves (deepenings) (12) at the top and at the bottom of the door leaf. These grooves (deepenings) (12) provide for an air gap (30) (seeFIG. 3) which is partially filled by a fire rated glass pane (9) in such a way that the ends of the fire rated glass pane (9) engage into the grooves (deepenings) (12). The fire rated glass pane (9) is supported by means of spacers (8) resting on the glass panes (4and5). Consequently a destruction of the fire rated glass pane (9) will preferably not occur, in case the fire rated glass pane (9) and/or the profiles (6and7) should expand.

An enameling (3) is preferably provided on the inside of the glass panes (4and5) in the area where these connect to the profiles (6and7). By doing so, it is likely guaranteed that the profiles (6and7), installed with the air gap, are not visible to the exterior side of the door leaf (see FIG.1). Simultaneously, it is guaranteed that the glass panes (4and5) are not executed with boreholes, which broadly ensures an increased fire protection.

The profiles (6and7) are preferably executed as solid profiles, maybe manufactured from light metal, plastic or wood or any other appropriate material. The profile (6) presents in its exterior closing region an exterior edge (14) with a possibly curved form.

The upper part ofFIG. 2broadly illustrates a door frame (31) which is mounted on an existing jamb (18), and which is covering mortar (23) over masonry (17). Is this case, the door frame (31) is broadly realized from two almost L-shaped additional profiles (19) covering the existing jamb (18). A sealing (21) is added preferably to seal the end where the additional profiles (19) connects to the mortar (23) on each side of the door frame (31). A gap remains between the two additional profiles (19), which is closed by means of a fire protection laminate in the form of a sealing profile (22). The additional profiles (19) are further sealed and fastened to the existing jamb (18) by means of a sealing (20) in the sealing profile (22) area. In the event of a fire, an automatic sealing of the space between the door frame (31) and the door leaf (2) see (FIG. 1) will possibly be achieved due to the intumescence of the fire protection laminate (22).

Profile (7) broadly distinguishes itself in the way that in a continuation of the profile projection (28) two legs (15) are conformed painting towards the floor (24). A groove (deepening) (16) is created between the two legs (15). This groove (deepening) (16) is possibly provided to mount e.g. door rails in the event the door is executed as a sliding door or to maybe connect other fittings. The legs (15) are provided to adapt the prefabricated fire rated door leaf (2) on site, to the required dimension. The optimum height of the fire rated door can possibly be adjusted by cutting the legs (15) on site without dismantling the door leaf.

FIG. 3is another embodiment example as the fire protection effect of the door leaf (2) (seeFIG. 1) is realized in a slightly different way. InFIG. 2a fire rated glass pane (9) is used between the two glass panes (4and5). However, inFIG. 3a fire protection material (26), preferably transparent and liquid is employed, between the two glass panes (4and5). To introduce the fire protection material (26) into the door leaf, spacer sections (25) are preferably incorporated with a certain distance (29) to the profiles (6and7) and into the grooves (deepenings) (12) to broadly create an air gap (30). The spacer section (25) is executed as a double-wall spacer section to broadly compensate in the event of the fire rated material's (26) possible expansion.

FIG. 4given in an overhead view, broadly shows a fire rated door of possibly the same type as in FIG.2. However,FIG. 4shows the fire rated door as center-pivoted (32), realized from profiles (6) in conjunction with a fire rated glass pane (9). Like inFIG. 2the door frame (31) ofFIG. 4consists of additional profiles (19) mounted on top of an existing jamb (18). Here, like inFIG. 2, the sealing profile (22) will possibly seal the center-pivoted door (32) with the door frame (31) in the event of fire.

FIG. 5given in an overhead view, broadly shows the center pivoted door (32) of FIG.4. However, inFIG. 5the center pivoted door (32) is installed inside an appropriate fire resistant jamb (18), which possibly does not have sealing profiles. Therefore, sealing profiles (1) in the form of fire protection laminates are broadly incorporated into the exterior edges (14) of the profiles (6) which are oriented towards the jamb (18).

FIG. 6given in an overhead view, broadly represents two center-pivoted door leaves (32) located side by side in a door frame. Like the door ofFIG. 5the two center-pivoted door leaves (32) ofFIG. 6are executed with sealing profiles (1) in the form of fire protection laminates in the zone that connects to the door frame (when the doors are closed) as well as in the zone that connects the two door leaves (when the doors are closed). The door frame is made from gypsum plasterboard (27) mounted on a sub-structure (33).

FIG. 7as given in an overhead view illustrates an example analogous toFIG. 6, however in this case the two center-pivoted door leaves (32) located side by side are installed in a capped jamb door frame similar to the one shown inFIGS. 2,3and4. Sealing of the doors is provided in the zone of the door frame by the installation of sealing profiles (22) between the additional profiles (19), and in the zone between the two doors by including a sealing profile (1) in the central region of the profiles (6).

Some examples of fire rated gels which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 5,885,713 issued to von Bonin, et al. on Mar. 23, 1999 and entitled “Fire-resistant glass containing a gel with improved melting resistance, and process for the preparation thereof”; U.S. Pat. No. 5,653,839 issued to Itoh, et al. on Aug. 5, 1997 and entitled “Fire-resistant glass and process for production hereof”; U.S. Pat. No. 5,624,998 issued to Itoh, et al. on Apr. 29, 1997 and entitled “Hardenable composition, aqueous gel and applications”; U.S. Pat. No. 5,519,088 issued to Itoh, et al. on May 21, 1996 and entitled “Hardenable composition, aqueous gel and applications thereof”; U.S. Pat. No. 5,496,640 issued to Bolton, et al. on Mar. 5, 1996 and entitled “Fire resistant transparent laminates”; U.S. Pat. No. 5,217,764 issued to Eich on Jun. 8, 1993 and entitled “Fire protection glazing”, all of these U.S. patents being hereby expressly incorporated by reference herein.

Some examples of transparent fire protection which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 5,462,805 issued to Sakamoto, et al. on Oct. 31, 1995 and entitled “Fire-protection and safety glass panel”; U.S. Pat. No. 5,425,901 issued to von Bonin, et al. on Jun. 20, 1995 and entitled “Fireproofing gels, processes for their preparation and their use, in particular for fireproof glazing”; U.S. Pat. No. 5,230,954 issued to Sakamoto, et al. on Jul. 27, 1993 and entitled “Fire-protection and safety composite glass panel”; U.S. Pat. No. 5,217,764 issued to Eich on Jun. 8, 1993 and entitled “Fire protection glazing”; U.S. Pat. No. 6,159,606 issued to Gelderie, et al. on Dec. 12, 2000 and entitled “Fire-resistant glazing panel”; U.S. Pat. No. 5,543,230 issued to von Bonin, et al. on Aug. 6, 1996 and entitled “Laminated glass construction having an intermediate layer of a fire-proofing gel”; U.S. Pat. No. 4,873,146 issued to Toussaint, et al. Oct. 10, 1989 and entitled “Transparent fire-screening panels”, all of these U.S. patents being hereby expressly incorporated by reference herein.

An example of fire rated glass which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 5,910,620 issued to O'Keeffe, et al. on Jun. 8, 1999 and entitled “Fire-rated glass and method for making same”, this U.S. patent being hereby expressly incorporated by reference herein.

Some examples of fire protection glass panes which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 5,380,569 issued to Kujas, et al. on Jan. 10, 1995 and entitled “Fire resistant glass partition”; U.S. Pat. No. 5,776,844 issued to Koch, et al. Jul. 7, 1998 and entitled “Compositions of silico-sodo-calcic glasses and their applications”; U.S. Pat. No. 5,958,812 issued to Koch, et al. Sep. 28, 1999 and entitled “Compositions of silico-sodo-calcic glasses and their applications”; U.S. Pat. No. 5,628,155 issued to Nolte, et al. May 13, 1997 and entitled “Fire-resistant structural component with glass pane”, all of these U.S. patents being hereby expressly incorporated by reference herein.

Some examples of enabling which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 6,043,171 issued to Siebers, et al. on Mar. 28, 2000 and entitled “Lead-free and cadmium-free glass compositions for glazing, enameling and decorating glass of glass-ceramics”; U.S. Pat. No. 5,782,999 issued to Kostrubanic on Jul. 21, 1998 and entitled “Steel for enameling and method of making it”; U.S. Pat. No. 5,633,090 issued to Rodek, et al. on May 27, 1997 and entitled “Lead-and cadmium-free glass composition for glazing, enameling and decorating glass”, all of these U.S. patents being hereby expressly incorporated by reference herein.

Some examples of fire rated doors which may possibly be incorporated in an embodiment of the present invention may be found in: U.S. Pat. No. 4,748,771 issued to Lehnert, et al. on Jun. 7, 1988 and entitled “Fire door”; U.S. Pat. No. 4,165,591 issued to Fitzgibbon on Aug. 28, 1979 and entitled “Component type building construction system”; U.S. Pat. No. 5,943,824 issued to Tatara on Aug. 31, 1999 and entitled “Fire rated, hinged, swinging door”; U.S. Pat. No. 6,183,023 issued to Yulkowski on Feb. 6, 2001 and entitled “Door with integrated fire exit device”; U.S. Pat. No. 5,896,907 issued to Dever, et al. on Apr. 27, 1999 and entitled “Rolling fire door including a door hold-open/release system”; U.S. Pat. No. 5,886,637 issued to Stuckey on Mar. 23, 1999 and entitled “Door with built-in smoke and fee detector”; U.S. Pat. No. 5,850,865 issued to Hsieh on Dec. 22, 1998 and entitled “Rolling fire door with delayed closing mechanism”; U.S. Pat. No. 5,565,274 issued to Perrone, Jr., et al. on Oct. 15, 1996 and entitled “Fire rated floor door and control system”, all of these U.S. patents being hereby expressly incorporated by reference herein.

Some examples of glass fiber reinforced plastic which may possibly be incorporated in an embodiment of the present invention, may be found in U.S. Pat. No. 5,868,080 issued to Wyler, et al. on Feb. 9, 1999 and entitled “Reinforced plastic pallets and methods of fabrication”; U.S. Pat. No. 5,634,847 issued to Shea on Jun. 3, 1997 and entitled “Fire Retardant reinforced plastic duct system”; U.S. Pat. No. 5,448,869 issued to Unruh, et al. on Sep. 12, 1995 and entitled “Composite framing member and window or door assembly incorporating a composite framing member”; U.S. Pat. No. 5,446,250 issued to Oka on Aug. 29, 1995 and entitled “Fiberglass reinforced plastic damping material”; U.S. Pat. No. 4,619,954 issued to Warner, II on Oct. 28, 1986 and entitled “Fiberglass reinforced plastic sheet material with fire retardant filler”; U.S. Pat. No. 4,676,041 issued to Ford on Jun. 30, 1987 and entitled “Corrosion-resistant door and its method of manufacture”, all of these U.S. patents being hereby expressly incorporated by reference herein.

The present invention also relates to a fire rated door or a fire rated window.

This application is a Continuation-In-Part application of International Patent Application No. PCT/EP00/06893, filed on Jul. 19, 2000, which claims priority from Federal Republic of Germany Patent Application No. 199 33 408.0, filed on Jul. 21, 1999. International Application No. PCT/EP00/06893 was pending as of the filing date of this application. The United States was an elected state in International Application No. PCT/EP00/06893.

More specifically the present invention relates to a fire rated door or a fire rated window which are installed in fire protection partitions, or a similar structure, to prevent or inhibit the spread of smoke and fire; said fire rated door or fire rated window comprises a mobile frame with its filling compartment which consists of a fire resistant material, and the mobile frame is partially or completely enclosed by a stationary frame component.

This fire rated door type is for example disclosed by European Patent Application No. 0 401 555 A2, where a glass pane is mounted in a metal frame equipped with a surrounding groove. In this case, the glass pane ends before the frame and is connected with the metal frame by means of Additional metal edge strips serving as compensating adapters. The metal strips are glued with traditional fire rated glue for example made on water-glass base.

European Patent Application No. 0 612 910 A2 displays a closing ledge for metal doors, which ledge, to increase stability in the lower part, is pressed between two protruding legs

A door frame profile for fire rated doors is disclosed by European Patent Application No. 0 444 393 A21 where a glass pane is retained in a strong door frame profile. The door frame profile is executed as hollow section and it presents, inserted into its chambers, fire rated plates that guarantee the fire resistance of such door.

A fire-resistant glazing is described in Federal Republic of Germany Patent Application No. 236 45 259 A1. In this case, silicate glass panes made from tempered glass are used on the one side, and a reinforced silicate glass pane is used on the other side of an intermediate air gap. The construction of such fire-resistant glazing is realized by means of a metal frame embracing and overlapping the border edge.

Federal Republic of Germany Patent Application No. 297 42 665 A1 reveals a fire retarding swing door or center pivoted door where the door frame respectively the borders of the door leaves present a thermal insulation material, extending over the entire length respectively the entire width. This thermal insulation material will expand when eat develops, such that in the event of fire, the door component includes a secure fire barrier. This door is composed of plane material, which is not transparent and, in a partial section, is interrupted by a window to be mounted.

The object of the invention is to conceive a fire rated door or a fire rated window abandoning the materials conventionally used for fire protection purposes, like light metal, wood or steel, and to manufacture said construction units at reduced cost.

The invention teaches that this object can be accomplished by the fire rated door and the fire rated window being comprised of a fire resistant plastic or synthetic material.

The dependent claims present further embodiments of the inventive idea.

It is therefore proposed to manufacture the mobile as well as the stationary door frame of a fire rated door or of a fire rated window with profiles made from a fire resistant plastic material. Fire rated doors and windows are installed into fire rated walls and in the event of danger, serve the purpose to stop the spread of a fire and also of smoke. For this reason, fire rated doors and fire rated windows are classified according to corresponding fire rating class. These individual fire-rating classes are organized according to the time the individual construction units will resist to a fire. The profiles, no matter whether they are solid profiles or hollow profiles with different cavities, are preferably arranged to build frames used for fire rated doors or fire rated windows. Either a multilayer glass pane, generally used as fire rated glass pane with correspondingly arranged fire protection layers, which will absorb the thermal radiation due to the heat development, or a fire resistant plastic material composed as plane material, can be employed as filling compartment within the frame.

According to the invention it is also conceivable, to manufacture the frame and the filling compartment as a single piece in moldings. Likewise in case of a low fire rating class, a fire rated door or a fire rated window may be arranged in that the frame manufactured from plastic is embedded between two glass panes. In this case, the spaced glass panes can extend as far as to the exterior border of the mobile frame. In case a higher fire rating class is chosen, a transparent fire protection material can be introduced between the spaced glass panes. This fire protection material can consist of a fire rated glass pane as described before or also of a liquid fire protection gel.

The fire resistant plastic material consists of a support material in form of endless glass fiber rovings arranged in axial direction of the profile. This “raw profile” is moreover reinforced in radial direction with an additional glass fiber complex. For this purpose, the glass fibers are impregnated with a resin matrix and hardened in a molding that corresponds to the profile'form. The molding is in this case heated to ensure a faster manufacturing process.

The employed resin matrix basically consists of unsaturated polyester resins including appropriate hardeners, accelerators, additives and this is the most important, fire retarding fillers. Corresponding colors are added in form of color pastes to achieve an adaptation to the aesthetics of existing buildings. Such fire rated doors can be executed as sliding doors, as well as single leaf or double feat doors with or without rebate. As the production of such profile forms is almost without limits, it is also possible to combine corresponding profiles.

With corresponding design, such mobile frame can also be manufactured from fire resistant plastic material as stationary frame. If hollow profiles are used, they can be filled partially or completely with fire protection material.

One feature of the invention resides broadly in a fire rated door or fire rated window to prevent the spread of smoke and fire, suitable for use in the region of a fire protection partition, said fire rated door or fire rated window comprises a mobile frame with its filling compartment which consists of a fire resistant material, and the mobile frame is partially or completely enclosed by a stationary frame component, characterized in that the fire rated door and the fire rated window consist of a fire resistant plastic material.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the mobile frame and the stationary frame are manufactured from profiles.

Still another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the filling compartment of the mobile frame partially or completely consists of fire resistant plastic material.

A further feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the filling compartment and the mobile frame consist of one single piece.

Another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the filling compartment of the mobile frame completely or partially consists of a fire rated glass pane.

Still another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the mobile frame is embedded between two spaced glass panes.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the glass panes extend as far as to the exterior edge of the frame.

A further feature of the invention resides broadly in a fire rated door or fire rated window characterized in that transparent fire protection material is included between the spaced glass panes.

Still another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the mobile and the stationary frame consist of solid material.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the mobile and the stationary frame consist of hollow profiles.

Another feature of the invention reside broadly in a fire rated door or fire rated window characterized in that the hollow profiles are completely or partially filled with a fire protection material.

Still another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the fire rated material is a fire protection glass pane.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the fie rated material is a fire protection gel.

A further feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the plastic material is a glass fiber reinforced plastic material.

Another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that glass fiber rovings, which are arranged in axial direction, are used as the support material in the plastic material.

Still another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the plastic profiles in radial direction are reinforced with a glass fiber complex, said glass fibers are impregnated with a resin matrix and hardened in a heated molding.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the resin matrix basically consists of unsaturated polyester resin, hardener, accelerator, additives, color pastes and fire retarding fillers.

A further feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the fire rated door is a single leaf or double leaf door.

Yet another feature of the invention resides broadly in a fire rated door or fire rated window characterized in that the fire rated door is a sliding door.

The following standards or codes, namely: ASTM D 523 entitled “Standard Test Method for Specular Gloss”; ASTM D635 entitled “Standard Test Method for Rate of Burning and/or Extent of and Time of Burning of Self-supporting Plastics in a Horizontal Position”; ASTM E 84 entitled “Standard Test method for Surface Burning Characteristics of Building Materials”; ASTM E 152 entitled “Standard Methods of Fire Tests of Door Assemblies”; NFPA 252 entitled “Standard Methods of Fire Tests of Door Assemblies”; and UL 10B entitled “Standard for Fire Tests of Door Assemblies”, are hereby incorporated by reference as if set forth in their entirety herein.

The terms fire rated, fire resistant, fire protection, and flame retardant are used herein interchangeably.

The term fire protection laminate or the like terminology is to mean, inter alia, a seal or similar structure made of intumescent material that expands in the event of a predetermined temperature or heat of fire. This expanded structure will then serve to seal off the space of a corresponding gap, say between a door jamb and a door leaf, to thereby enhance the fire rated capability of the fire rated door, and a fire rated window.

Some examples of fire resistant plastic, or polymeric or synthetic, materials which may possibly be incorporated in an embodiment of the present invention are to be found in: U.S. Pat. No. 4,017,457 issued to Baron et al. on Apr. 12, 1977 and entitled “Flame retardant polycarborate compositions”; U.S. Pat. No. 4,035,447 issued to T noki et al. on Jul. 12, 1977 and entitled “Fire resistant polymer composition”; U.S. Pat. No. 4,101,498 issued to Snyder on Jul. 18, 1978 and entitled “Fire-resistant compositions”; U.S. Pat. No. 5,444,809 issued to Aoki et al. on Ang. 22, 1995 and entitled “Flame retardant resin composition and flame retardant plastic optical fiber cable using the same”; U.S. Pat No. 4,119,612 issued to Vollkommer et al. on Oct. 10, 1978 and entitled “Polymeric and oligameric formals”; U.S. Pat. No. 4,650,823 issued to Krishnan et al. on Mar. 17, 1987 and entitled “Iron oxide pigmented, polycarbonate compositions”; U.S. Pat No. 5,276,077 issued to Schwane et al. on Jan. 4, 1994 and entitled “Ignition resistant carbonate polymer blends”; U.S. Pat. No. 5,298,299 issued to Shea on Mar. 29, 1994 and entitled “Double wall fire proof duct”; U.S. Pat. No. 5,326,805 issued to Sicken et al. on Jul. 5, 1994 and entitled “Flame-retardant plastics molding composition of improved stability”, U.S. Pat. No. 5,329,972 issued to Guiton on Jul. 19, 1994 and entitled “Fire resistant plastic structure”; U.S. Pat. No. 5,444,809 issued to Aoki et al. on Aug. 22, 1995 and entitled “Flame retardant resin composition and frame retardant plastic optical fiber cable using the same”; U.S. Pat. No. 5,571,888 issued to Cheng et al. on Nov. 9, 1996 and entitled “Process for preparing flame-retardant phosphorous-containing unsaturated polyester”; and U.S. Pat. No. 6,110,559 issued to De Keyser on Aug. 29, 2000 and entitled “Plastic article having flame retardant properties”, all of these U.S. patents being hereby expressly incorporated by reference as if set forth in their entirety berein.

Some examples of fire resistant materials which possibly may be incorporated in an embodiment of the present invention are to be found in: U.S. Pat. No. 3,983,082 issued to Pratt et al. on Sep. 28, 1976 and entitled “Intumescent fire retardant material and article”; U.S. Pat. No. 4,052,526 issued to Pratt et al. on Oct. 4, 1977 and entitIed “Intumescent fire retardant material and article”; U.S. Pat. No. 4,065,394 issued to Pratt et al. on Dec. 27, 1977 and entitled “Intumescent fire retardant material”; U.S. Pat. No. 4,235,836 issued to Wassell et al. on Nov. 25, 1980 and entitled “Method for making thermal insulating, fire resistant material”; U.S. Pat. No. 4,246,358 issued to Ellard on Jan. 20, 1981 and entitled “Fire-resistant material and process”; U.S. Pat. No. 4,255,317 issued to Knecht on May 5, 1981 and entitled “Fire resistant material”; U.S. Pat. No. 4,810,741 issued to Kim and entitled “Fire-resistant material, noncombustible material for treating interior building material and processes for their production”; U.S. Pat. No. 5,401,793 issued to Kobayashi et al. on Mar. 28, 1995 and entitled “Intumescent fire-resistant coating, fire-resistant material, and processes for producing the fire-resistant material”; U.S. Pat. No. 6,001,285 issued to Wunram on Dec. 14, 1999 and entitled “Fire-retardant material and a method for the manufacture of such a material”; and U.S. Pat. No. 6,159,878 issued to Marsh on Dec. 12, 2000 and entitled “Layered reflecting and photo luminous fire resistant material”, all of these U.S. patents being hereby expressly incorporated by reference as if set forth in their entirety herein.

Some examples of fire retardant fillers which possibly may be incorporated in an embodiment of the present invention are to be found in: U.S. Pat. No. 4,254,177 issued to Fulmer on Mar. 3, 1981 and entitled “Fire-retardant product and method of making”; U.S. Pat. No. 4,391,924 issued to Uram, Jr. on Jul. 5, 1983 and entitled “High temperature thermobarrier compositions”; U.S. Pat. No. 4,619,954 issued to Warner, II on Oct. 28, 1986 and entitled “Fiberglass reinforced plastic sheet material with fire retardant filler”; U.S. Pat. No. 4,746,565 issued to Bafford et al. on May 24, 1988 and entitled “Fire barrier fabrics”; U.S. Pat. No. 4,839,222 issued to Jain on Jun. 13, 1989 and entitled “Fiberglass insulation coated with a heat collapsible foam composition”; U.S. Pat. No. 5,039,718 issued to Ashley et al. on Aug. 13, 1991 and entitled “Fillers”; U.S. Pat. No. 5,279,894 issued to Hoffman et al. on Jan. 18, 1994 and entitled “Curable silicone compositions and non-flammable cured products obtained therefrom”; U.S. Pat. No. 5,378 issued to Chen on Jan. 3, 1995 and entitled “Cross-linked melt processible fire-retardant ethylene polymer compositions”; U.S. Pat. No. 5,474,602 issued to Brown et al. on Dec. 12, 1995 and entitled “Treatment of magnesium hydroxide and its use as plastics filler”; and U.S. Pat. No. 6,100,359 issued to Ghatan on Aug. 8, 2000 and entitled “Ablative polyurea foam and prepolymer”, all of these U.S. patents being hereby expressly incorporated by reference as if set forth in their entirety herein.

The invention as described herein above in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.

Index of Reference Numerals