EP4166743A1 - Inlay for doors - Google Patents

Abstract

The invention relates to an inlay for the production of doors, with a sandwich panel which has at least two layers, the layers being connected in sections with an adhesive. In order to provide a lightweight door and a lightweight door panel with a thickness of at least 60 mm, which can meet the increasingly stringent requirements in the field of soundproofing and fire protection, it is envisaged that the layers will be mineral panels, the mineral panels will be one density from 340 kg/m³ to 420 kg/m³, in particular 380 kg/m³ to 420 kg/m³ /sup> and have a thickness of 15 mm to 31 mm and between the layers there is a gap with a thickness of 0.4 mm to 3 mm, in particular between 0.5 mm and 2 mm.

Description

The invention relates to an inlay for the production of doors, with a sandwich panel that has at least two layers, the layers being connected in sections, and a door with such an inlay.

Inlays made of sandwich panels are provided for the manufacture of doors that are used as interior doors, apartment entrance doors or exterior doors. In addition to the sandwich panel, the inlays often include framing timbers. To complete the door, the inlays are decoratively coated and/or receive additional layers or protective covers and corresponding door fittings. Metal doors, for example, are given an external metal surface, while wooden doors are often given external decorative layers of laminate or veneer layers.

As with all building materials, the requirements for doors are also increasing. In particular, the expectations in terms of the soundproofing performance of the doors are constantly being raised, although the doors should not become heavier, stronger or more expensive if possible. In addition, there are often specific fire behavior requirements that the doors must meet.

To achieve the properties, the manufacturers mostly use self-developed sandwich structures, which provide you with selected individual layers of different materials in a specific order. A core problem is that the known sandwich structures for interior doors and apartment entrance doors with the same normal door thicknesses and weights that are usual today hardly achieve sound insulation values in the range of more than 42 dB or only with very complex sandwich structures and expensive materials. In the case of thick doors in the range of 60 mm or more, in particular, these are often extremely heavy in order to achieve the current sound insulation values.

Regardless of the materials, it has been found that decoupling the individual layers from one another can be advantageous in order to achieve high sound insulation values. This is usually achieved in that individual layers are only connected to one another in sections, for example using adhesive dots or else clip systems. A generally advantageous arrangement of the adhesive points, which brings about an improvement in the sound reduction index independently of the materials used, has not yet emerged, but the arrangement of the adhesive points or the necessary adhesive surfaces are often dependent on the materials used in the individual layers of the sandwich panel.

The object of the invention is therefore to provide a lightweight inlay for doors with which the increasingly stringent requirements in the area of sound insulation and fire protection can be met, in particular sound insulation values of 42 dB measured according to EN ISO 10140-2 can be reliably achieved.

The invention solves the problem by an inlay according to claim 1 and a door according to claim 9, by an inlay for a door blank according to claim 10, a door blank with an inlay according to claim 11, doors according to claim 12 and 13, use of an insulating layer according to claim 14 and a method according to claim 15. Advantageous developments of the invention are specified in the dependent claims. All of the features described are fundamentally the subject matter of the invention, either individually or in any combination, regardless of how they are summarized in the claims or how they relate back to them.

The inventive inlay for the production of doors comprises a sandwich panel which has at least two layers connected in sections, the layers being mineral panels which have a density of 340 kg/m ³ to 420 kg/m ³ , in particular 380 kg/m ³ to 420 kg/m ³ and a thickness of 15 mm to 31 mm, in particular 20 mm +/-1 mm and a gap between the layers with a thickness of 0.4 mm to 3 mm, in particular from 0.5 mm to 2 mm is arranged.

The inlay has no further decoupling layers made of paper, foam, etc., for example.

It has been found that mineral panels (preferably in the form of mineral fiber panels or mineral wool panels) with a density of 340 to 420 kg/m ³ , in particular 380 to 420 kg/m ³ , have particularly good sound insulation values (measured according to DIN EN ISO 10140-2). the inlay and the doors made from it. Surprisingly, it has also turned out that the sound insulation values tend to deteriorate, especially in the case of mineral panels with higher or lower densities. The density is in a range that keeps the overall weight of the inlay and thus also the later door low. The layers of the inlay are made up of at least largely identical material, so that particularly simple processing is also made possible. In addition to the identical material, the layers are preferably also constructed at least largely identically in terms of their dimensions, as a result of which the high sound insulation values can be achieved in a particularly simple manner. In particular, the inlay does not include any further layers in addition to the mineral plates.

In addition to the surprisingly good sound insulation already mentioned, the mineral panels (hereinafter also referred to as mineral panels always include the above-mentioned mineral fiber panels or mineral wool panels) can also absorb high loads in terms of fire protection, since they inherently have a high level of fire protection. In particular, the mineral panels contain a mineral wool mix of rock wool and/or glass wool. In addition to the rock wool and/or glass wool components, the mineral panels comprise a binder, preferably based on renewable raw materials, advantageously a binder based on renewable raw materials, in particular based on corn starch and/or wheat starch. Mineral panels have also proven to be particularly suitable for high formwork protection, which have a proportion of 30% to 60% mineral wool, in particular biosoluble mineral wool, 20% to 30% natural fillers, in particular sand and/or chalk, 5% to 10% organic Binding agents, in particular based on corn starch and/or wheat starch and having a cellulose content of up to a maximum of 0%. The mineral plates have a flexural rigidity that allows the mineral plates to be handled easily by machine and/or by hand in the manufacturing process. Particularly good sound insulation values were achieved with such mineral panels. Mat-like mineral bodies, which are often known from the field of thermal insulation, for example, However, they do not have any flexural rigidity that characterizes these mineral bodies as plates, are not mineral plates within the meaning of the invention.

Regardless of the materials, it has been found that decoupling individual layers from one another can be advantageous in order to achieve high sound insulation values for sandwich panels. This is achieved, for example, by using sound-insulating intermediate layers. Individual layers are also only connected to one another in sections, for example using adhesive dots or clip systems. A generally advantageous arrangement of the adhesive points, which brings about an improvement in the sound reduction index independently of the materials used, has not yet emerged, but the arrangement of the adhesive points or the necessary adhesive surfaces are often dependent on the materials used in the individual layers of the sandwich panel.

In addition to the connection in sections, it is provided according to the invention that a gap, usually an air gap, is formed between the layers, i. that is, there is a gap between mating surfaces of the plies. It was surprisingly found here that in the case of layers of mineral plates, the gap should preferably have a thickness of between 0.4 mm and a maximum of 3 mm, preferably between 0.4 mm and a maximum of 2.5 mm, particularly preferably between 0.5 and 2 mm , in order to achieve particularly high soundproofing performance.

In a door, the inventive inlay achieves a sound insulation value of at least 42 dB measured according to DIN EN ISO 10140-2 and a fire resistance EI 60 measured according to EN 1634-1. The inlay is designed for a door. That is, to complete the door, the inlay is either covered with metal sheets (metal door), in particular surrounded by two metal shells, or provided with additional cover layers (e.g. HDF panels between 2 mm and 6 mm thick), which then have a corresponding decorative coating so that it is not visible on the subsequent door. Due to the high sound insulation values and the low density, the structurally very simple inlay enables the production of both thin doors (in the range of approx. 40 mm) and strong doors (in the range from approx. 50 mm to 55 mm) with low weight , good sound insulation and very good fire protection.

According to a development of the invention, the sandwich is constructed in at least three layers, with a middle layer and outer layers arranged on opposite sides of the middle layer. The three-layer structure makes it even easier to achieve the high sound insulation values, so that sound insulation values of over 42 db can easily be achieved for the later door. The third or possibly further layers of mineral plates are also largely identical in terms of material and structural design to the two layers. In addition, a corresponding gap is also formed between the layers in the case of a three-layer or multi-layer design. Inlays according to the invention with a three-layer structure made of mineral plates are preferred, since these achieve optimum sound insulation values with minimal effort.

While two-layer inlays are preferably intended for approx. 40 mm thick doors, the three-layer inlays in particular can be used for approx. 60 mm thick doors. Accordingly, with a two-layer structure, the mineral plates have a preferred thickness of approx. 15 mm to approx. 20 mm (each +/-1 mm, in particular 19.3 mm +/-0.3 mm, while with a three-layer structure and 60 mm, the mineral plates have a thickness between 18.5 mm and 20.5 mm, in particular 19.3 mm +/- 0.3 mm.Two-layer structures with thick mineral plates up to approx used in particular for thick doors with a thickness of approximately 60 mm However, door thicknesses of up to 80 mm or 90 mm and then in particular a three-layer structure are also conceivable.

The connection in sections is understood to mean sections at which the layers are connected and in which there is therefore no gap (since this is filled with an agent) between the respective layers, but there is a distance between the respective surfaces. The connection can be made, for example, by means of clamps or similar mechanical connection means. The layers are particularly preferably glued together with an adhesive arranged in sections. The distance between the respective layers is particularly preferably formed by means of an adhesive which is arranged with a corresponding thickness and creates a gap. Alternatively or additionally, spacers are arranged between the layers to produce the gap. The bonding is then, for example. About the spacers, each with their opposite sides are glued to the surfaces of the layers that are walled together, ie, for example, the middle layer and the outer layer. Of course, the gap between the layers is thus present (in the direction parallel to the surface of the layers) at least in the area between the adhesive sections and/or the spacers. The distance between mutually facing or connected surfaces of the layers should be as homogeneous as possible, also in the area of the adhesive and/or the spacers. The layers are thus also largely aligned parallel to one another.

The spacers can be made of different materials, such as cardboard, wood, rubber or the like. According to a development of the invention, it is provided that the spacers comprise the material of the mineral plates and/or perlite, in particular are formed from it. On the one hand, the material of the mineral plates and/or perlite also ensures good fire resistance and low sound transmission. On the other hand, mineral plate residues and/or perlite residues or door sections or inlays with appropriate spacers are particularly easy to recycle, for example.

Water glass adhesive, for example, is used as an adhesive for inlays. In connection with the inventive inlay made of mineral plates, adhesives based on cyanoacrylate, isocyanate and/or polyurethane are particularly preferably used, since they enable the layers to be bonded particularly securely using a small amount of adhesive.

The adhesive between the layers is preferably arranged in sections. In the field of door manufacture, for example, punctiform bonding is known as sectional bonding. In order to achieve a connection between the layers of the sandwich that is sufficient for transport and handling in further processing, the adhesive is arranged between the layers as uninterrupted linear adhesive strands. The adhesive preferably covers between 50% and 5%, in particular below 40% to 5%, particularly preferably below 30% to 5%, of the surface of the respective areas of the layers to be bonded. The Adhesive strands are preferably between 25 mm and 40 mm wide, in particular 30 mm +/- 5 mm.

A particularly preferred embodiment of the invention provides that the spacers are present in the adhesive and are applied with the adhesive. Here, for example, a full-surface application of the adhesive would also be conceivable, with the bonding nevertheless taking place only in the area of the spacers due to the spacers. The size of the spacers ultimately determines the gap width. However, the spacers are particularly preferably oversized, ie they are larger than the later gap. In order to produce a sandwich with such spacers, the spacers are applied, e.g. together with the adhesive, the two mineral plates are placed one on top of the other and then, e.g. pressed together in a press, with the spacers being pressed into the surfaces of the mineral plates. In this way, it is particularly easy to produce a target gap thickness between the mineral slabs and there is a particularly good bonding of the slabs in sections, since the spacers are bonded to the respective slabs with a larger surface area.

When using mineral plates, according to a development of the invention, the adhesive is particularly preferably arranged in the area of the outer edges of the layers and as adhesive strands extending diagonally to the outer edges of the sandwich plate. It has been found that diagonal strips of adhesive aligned at an angle of between 30° and 60°, particularly advantageously at an angle of 45° to the longitudinal side edges, have a particularly positive effect and enable simple production of the inlays.

Alternatively, the adhesives can also be arranged in a punctiform manner in accordance with the statements below. The application of the adhesive in the area of the outer edges primarily serves to improve the handling of the layers connected to one another. In the subsequent door (blank) manufacturing process, the inlays are often cut to a final length and width, as a result of which the adhesive applied to the outside area is cut off on at least one or both of the respective long sides.

Outstanding insulation performance is achieved with an inlay made of two spaced-apart mineral panels, on which soft insulation layers are arranged on the outside. A soft insulating layer is understood to mean that its surface can be depressed manually, in particular with a fingernail. The soft insulating layer is designed as a flexible mat and can therefore easily be rolled up to the usual size used for doors (approx. 1 m × approx. 2 m). The soft insulation layer is therefore not a panel, as it lacks the necessary basic rigidity, but is designed as a mat.

The insulating layer comprising a permanently elastic material, in particular a plastic-based one, comprises, for example, a rubber, for example a rubber mat, in particular a permanently elastic plastic, and is preferably designed as a permanently elastic insulating layer. The plastic-based insulation layer preferably comprises a mineral filler, for example chalk and/or sand, and a plastic material as a binder. The insulating layers can be coated on their surfaces with a foil, a fabric, in particular a PET foil or the like, for example for better handling. The density of the plastic-based insulating layer is at least 1100 kg/m ³ , particularly preferably at least 1250 kg/m ³ , advantageously at least 1300 kg/m ³ and particularly advantageously at least 1450 kg/m ³ . The maximum density is 1,800 kg/m ³ . The density of the insulating layer is particularly preferably 1,250 kg/m ³ to 1500 kg/m ³ . The soft insulating layer is preferably 2 mm to 6 mm thick.

The object on which the invention is based is also achieved by a door for use as an interior door, apartment entrance door and/or exterior door with an inlay as described above. Such a door can, for example, have two metal shells surrounding the inlay. Such a door can also comprise outer layers designed as decorative cover sides, for example.

In the case of a door designed as a metal door, the inlay is completely surrounded by metal panels. This is preferably done using two metal shells that together cover the 6 sides of the inlay. The metal shells are usually glued to the inlay. This is done, for example, over the entire surface. However, three are particularly preferred Adhesive strips arranged, which extend in the longitudinal direction of the door. The strips are particularly preferably between 80 mm and 120 mm wide, in particular 100 mm +/-15 mm, in order to obtain optimal acoustic decoupling of the metal shells from the inlay. In this case, two strips are preferably arranged in the region of the opposite longitudinal side edge and the third strip is arranged at least largely in the middle between the side edge strips. Surprisingly, exactly this arrangement and orientation has turned out to be particularly suitable for achieving the high sound insulation values. The adhesives can be used as adhesives for gluing the layers of the inlay, which keeps production simple.

According to a development of the invention, it is provided that the layers of the inlay are glued in the door by means of adhesive strips arranged diagonally and arranged on a short and a long side edge of the layers. The above-described bonding of the layers of the inlay on both opposite side edges to produce the inlay—as already described above with regard to the adhesive—primarily has the purpose of making the inlay easy to handle and easy to transport. The inlay is also usually produced in a slightly larger size (length, width) than the later door. For door production, the inlay is reduced (cut) again to the final size in the door, at least on a short and a long side edge. Surprisingly, it turned out that adhesive bonds between the layers can be cut off (removed) on a short and a long side edge. This simple one-sided trimming (i.e. short on one side and long on one side) of the inlays keeps the manufacturing process of the inlays and the doors simple and sufficient structural strength with easily achievable good sound insulation values is still guaranteed.

The object is also achieved by an inlay for a door blank for the production of interior doors and apartment entrance doors, with a sandwich panel having at least one middle layer made of a panel with two opposite main surfaces and at least one adjoining further sandwich layer on each of the main surfaces of the middle layer, characterized in that the middle layer has a thickness of at least 20 mm and a density between 160 kg/m ³ and 450 kg/m ³ , and the sandwich layers arranged on the middle layer with the middle layer connected in sections and are each designed as a soft insulation layer made of a permanently elastic material, in particular based on plastic with a thickness between 2 mm and 6 mm and a density between 1,100 kg/m ³ and 1,800 kg/m ³ .

The inventive inlay with a sandwich panel comprises at least one middle layer made of a panel with two opposite main surfaces and on each of the main surfaces of the middle layer at least one adjoining further sandwich layer, the middle layer having a thickness of at least 20 mm, preferably at least 25 mm and a density between 160 kg/m ³ to 450 kg/m ³ and the sandwich layers arranged on the middle layer are connected to the middle layer, e.g. in sections and each as a soft insulating layer made of a permanently elastic material, in particular based on plastic with a thickness between 2 mm and 6 mm and a Density between 1150 kg/m ³ and 1,800 kg/m ³ are formed.

The innovative inlay already achieves very good sound insulation values of at least 37 db thanks to its special combination of a middle layer made of a panel with very low density and soft, plastic-based insulation layers with high densities arranged on the middle layer and directly connected to it. The inlay enables the provision of door blanks that have sound insulation values of at least 42 db measured according to DIN EN ISO 10140-2 through a simple direct connection of the insulating layer with conventional outer layers with high densities and hard surfaces, e.g. HDF. The connection between the insulating layer and the outer layer can take place via a simple full-surface adhesive bond, for example via a simple full-surface adhesive bond with a white glue.

While the well-known combination of a panel with a very low density and outer layers with a high density already achieves very good sound insulation values, the soft insulation layer made of a permanently elastic material, in particular a plastic-based one, surprisingly enables a considerable increase in the sound insulation performance, which means that door blanks with sound insulation values of over 42 db are easily achieved and only the inlay achieves sound insulation values of at least 37 db. As a result, for example, thin door blanks with a thickness of approx. 40 mm and a sound insulation performance of 42 db can also be easily provided.

A soft insulation layer is understood to mean an insulation layer whose surface can be pressed in manually with a fingernail in particular. The soft insulating layer is designed as a flexible mat and can therefore easily be rolled up to the usual size used for doors (approx. 1 m × approx. 2 m). The soft insulation layer is therefore not a panel, as it lacks the necessary basic rigidity, but is designed as a mat.

The insulating layer comprising a permanently elastic material, in particular a plastic-based one, comprises, for example, a rubber, for example a rubber mat, in particular a permanently elastic plastic, and is preferably designed as a permanently elastic insulating layer. The plastic-based insulation layer preferably comprises a mineral filler, for example chalk or sand, and a plastic material as a binder. The insulating layers can be coated on their surfaces with a foil, a fabric, in particular a PET foil or the like, for example for better handling. The density of the plastic-based insulating layer is at least 1100 kg/m ³ , particularly preferably at least 1250 kg/m ³ , advantageously at least 1300 kg/m ³ and particularly advantageously at least 1450 kg/m ³ . The maximum density is 1,800 kg/m ³ . The density of the insulating layer is particularly preferably 1,250 kg/m ³ to 1500 kg/m ³ .

The middle layer is particularly preferably made of chipboard or fibreboard, since this type of board inherently has good sound insulation values, high rigidity and sufficient stability for a door. Surprisingly, however, it has been found that significantly better sound insulation values can be achieved or high sound insulation values can be achieved more easily by means of certain chipboard or fiber boards. According to a development of the invention, it is provided that the middle layer comprises at least one flax board designed as chipboard or fibreboard, with a density of between 300 kg/m ³ and 400 kg/m ³ . The flax boards can basically be designed as chipboard. However, flax fiber boards are preferably used, since these bring special advantages in terms of sound insulation values, which are based on the flax fiber material. The specified density ranges for the flax boards have proven to be particularly suitable, which are also particularly easy to produce for flax boards. Ultimately, there are also the particularly small ones Cost is advantageous for flax boards with the low density in the range between 300 kg/m ³ and 400 kg/m ³ .

According to a development of the invention, another particularly suitable board that can be used as a middle layer is mineral boards, in particular mineral fiber boards in the density range from approx. 320 kg/m ³ to approx. 450 kg/m ³ , in particular with a density of approx. 380 kg/m ³ to approx. 420 kg/ ^m3 (400 kg/ ^m3 +/-20 kg/ ^m3 ). Mineral boards, in particular mineral fiber boards, which are designed as mineral wool boards, for example, have proven to be well suited. In addition to particularly good sound insulation, they can also absorb high loads in the area of fire protection. In addition to the rock wool and/or glass wool components, the mineral panels (hereinafter also referred to in particular as mineral fiber panels or mineral wool panels) comprise a binder, preferably based on renewable raw materials, advantageously a binder based on renewable raw materials, in particular based on corn starch and/or or wheat starch. Mineral panels have also proven to be particularly suitable for high formwork protection, which have a proportion of 30% to 60% mineral wool, in particular biosoluble mineral wool, 20% to 30% natural fillers, in particular sand and/or chalk, 5% to 10% organic Binding agents, in particular based on corn starch and/or wheat starch and having a cellulose content of up to a maximum of 0%.

The mineral plates have a flexural rigidity that allows the mineral plates to be handled easily by machine and/or by hand in the manufacturing process. Particularly good sound insulation values were achieved with such panels. Mat-like mineral bodies, which are often known from the field of thermal insulation, for example, but which do not have the flexural rigidity that characterizes these mineral bodies as plates, are not mineral plates within the meaning of the invention.

The technical properties of an interior door or apartment entrance door also depend heavily on the strength of the door. A basic goal is to achieve sound insulation values for door thicknesses of 46 mm +/-1 mm of at least 42 db, preferably higher, measured according to DIN EN ISO 10140-2 and with the lowest possible weight. In order to be able to meet the technical requirements, however, they are common today In order not to exceed standard thicknesses for the respective doors, according to a development of the invention, the middle layer has a thickness of between approx. 26 mm and approx. 65 mm, in particular between 26 mm and 38 mm. The middle layer can consist of a one-piece chipboard or fiberboard. In terms of production, however, it can also be advantageous to connect several chipboards or fibreboards with one another in order to achieve the specified thickness of the middle layer. In this case, the chipboard or fibreboard are in particular connected over the entire surface, for example glued to one another over the entire surface. In special designs and in order to achieve particularly high sound insulation performance, the chipboard or fiberboard can also be spaced apart from one another, for example connected with a few spacers. In principle, middle layers up to a thickness of 100 mm are also conceivable in the field of flax fiber boards.

The middle layer can, for example, be formed from two chipboard or fiberboards, which are at least partially connected to one another, e.g. B. are glued or stapled.

The plastic-based insulation layer in particular easily achieves good sound insulation values in combination with the stressed middle layer, in particular a middle layer made of flax fibers or mineral fibers, for example mineral wool. It turned out that the sound insulation values are also dependent on the type of plastic in the plastic-based insulating layer. The insulating layer based on polyurethane is particularly preferred for the first described inlay for the production of doors with two layers of mineral plates as well as for the inlay described here with at least one layer and two insulating layers, since it has particularly good sound insulation values. Surprisingly, it has also turned out that precisely insulating layers which are based on renewable raw materials, in particular polyurethanes produced from renewable raw materials, are particularly suitable as an insulating layer. Insulating layers which have fillers, in particular sand and/or chalk, have proven to be particularly advantageous.

A further improvement in the soundproofing values can be achieved—likewise with regard to both inlays—by at least one surface of the insulating layer being coated with a reinforcing layer, with preferably both opposite main surfaces of the insulation layer are equipped with a reinforcing layer. On the one hand, the reinforcement layer strengthens the surface of the insulating layer, which prevents damage, for example, and on the other hand, it decouples the insulating layer from the middle layer or, in the case of an outward-facing arrangement, from the outer layers. The reinforcement layer is firmly connected to the insulating layer (cannot be removed without destroying it) and over the entire surface. In addition to the indicated decoupling, the reinforcement layer also prevents cracks in the surface of the insulation layer, which can occur during processing, for example.

The advantageous effects of the reinforcement layer can be achieved, for example, by means of a reinforcement layer that is designed as a woven fabric, knitted fabric or scrim. However, the reinforcement layer is particularly preferably designed as a fleece with a correspondingly rough surface. In addition to the effects listed, the reinforcement layer also facilitates the processability of the insulating layer, particularly in the case of reinforcement layers arranged on both sides. A reinforcement layer with PET fleece is advantageous for ease of processing, preferably with a standard wood adhesive, in particular a white glue (PVAC glue).

The sectional bonding of the layers of a sandwich panel in the area of door blanks is known in principle. In the case of the inlays and door blanks according to the invention with a plastic-based insulation layer, however, it has been found that the area formed by the adhesive sections and the number of adhesive sections can contribute significantly to easily achieving the sound insulation values of at least 42 db. Therefore, according to a further development of the invention between the (each) insulation layer and middle layer per 1 m ² middle layer between 4-6 adhesive points are arranged, each with an adhesive surface between approx. 55 cm ² to approx. 114 cm ² . The dots of adhesive are preferably applied as round or at least rounded dots of adhesive, but they can also have an angular shape or, for example, be in the form of lines. A particularly good soundproofing is achieved with a distribution of the adhesive points in which the adhesive points are arranged in rows and columns. It has turned out to be particularly advantageous that the distances between the adhesive centers and the distances between the two outer adhesive centers of a line are as equal as possible to the adjacent outer sides. The same applies to the distances between the center points of the columns.

For example, in the case of outer layers that are subjected to particularly high mechanical loads, smaller adhesive points can also be arranged in addition to the above-mentioned 4-6 (larger) adhesive points per 1 m ² sandwich panel. Here, too, a special design of the adhesive points and the adhesive surfaces produced by them has proven to be advantageous. According to a development of the invention, it is provided that between each insulation layer and the middle layer per 1 m ² middle layer 4-6 (large) adhesive centers each with an adhesive surface between approx. 55 cm ² to approx. 114 cm ² and 6-14 (small ) adhesive center points are arranged, each with an adhesive area between about 0.77 cm ² to about 7.1 cm ² . Here, too, the adhesive dots are preferably applied as round or at least rounded adhesive dots.

As an alternative to the aforementioned variants with 4-6 large dots of adhesive, the section-by-section connection of the insulating layer with the middle layer can also be achieved using a large number of small dots of adhesive while maintaining the high sound insulation values. According to a development of the invention, it is provided that between 22 and 26 adhesive points each having an adhesive surface of between approx. 0.77 cm ² and approx. 7.1 cm ² are arranged between the insulating layer and the middle layer per 1 m ² middle layer. The geometric shape of the adhesive center points can be arbitrary, for example as polygonal or knitted adhesive center points. The adhesive points are preferably designed as round or at least rounded adhesive points. These small dots of adhesive are also preferably distributed approximately symmetrically over the surface of the middle layer.

When using two mineral panels connected in sections as a middle layer, the arrangement of the adhesive described in the two previous paragraphs for gluing the mineral panels to the insulating layers is possible, but not absolutely necessary to achieve a sound insulation value of 42 dB. Full-surface bonding of the mineral panels with the insulating layers is also sufficient here. However, the above-described arrangement of the adhesive for gluing the insulating layer to the middle layer can also be used to glue the layers of a middle layer (or the two Layers of a sandwich panel) are used, especially in layers that are not designed as mineral panels..

The object on which the invention is based is also achieved by a door blank with one of the inlays described above, the insulating layers or the two layers of mineral plates being connected to hard outer layers to form the door blank, the outer layers having a density of at least 850 kg/m ³ and the surfaces the outer layers are hard compared to the soft surface of the insulating layers or the surfaces of the mineral panels.

The outer layers are not only responsible for the acoustic characteristics of the door blank, but can also determine the structural strength and serviceability of the doors, for example. A high density of the outer layer with at least one hard surface is advantageous for the acoustic properties. The combination of inventive inlays with an outer layer arranged directly on the insulating layers and having at least one hard surface makes it particularly easy to provide a door blank that achieves the aforementioned sound insulation values of at least 42 db. The outer layers of the door blank can be designed either for further coating with a decorative layer/coating or already as a decorative and final outer layer (top layer).

The outer layer can be formed, for example, from a metallic plate, for example an aluminum plate or steel plate. The outer layer is preferably made of chipboard or fibreboard with a high density of at least 850 kg/m ³ , preferably 950 to 1050 kg/m ³ . The outer layers of fiberboard are preferably designed as HDF (high density fiberboard) or HF board (hard fiberboard). The outer layers preferably each have a thickness of between 3 mm and 6 mm. The outer layers can also have a coating on the inside with a moisture barrier, e.g. a metal foil, in particular an aluminum foil with a thickness of approx provide climate door.

Hard outer layers are to be understood as meaning outer layers whose surface is opposite the surface of the insulating layer or the surface of the mineral plate is hard, e.g. cannot be pressed in with a fingernail. The outer layers, as well as the middle layer, are preferably designed as panels and thus have a high basic rigidity, which the insulating layer does not include.

The object on which the invention is based is also achieved by a door for use as an interior door or apartment entrance door with one of the inlays described above or by a door for use as an interior door or apartment entrance door with the door blank described above.

The object on which the invention is based is also achieved by using at least two insulation layers, each about 2 mm to about 6 mm thick, made of a permanently elastic material, in particular based on plastic, in particular polyurethane with a density between 1100 kg/m ³ and 1800 kg/m ³ in an inlay for a door blank for the production of interior doors and apartment entrance doors with a sandwich panel which has a middle layer of at least one panel with a density between 160 kg/m ³ and 450 kg/m ³ .

The insulating layer is preferably used in an inlay that is used in a door blank that has outer layers with a density of at least 900 kg/m ³ , surfaces of the outer layers being hard compared to the soft surfaces of the insulating layer. The insulation layers are preferably polyurethane-based insulation mats.

The insulating layers are particularly preferably used as a layer arranged between the middle layer and the outer layers. According to a development of the invention, it is provided that the insulating layers are used together with at least one flax board, in particular flax fiber board, designed as a middle layer. It is further preferred that only the insulating layer (with the respective adhesive layers between the outer layer-insulating layer and the middle layer-insulating layer) is arranged between the middle layer and the outer layer.

Regarding the stated and other features of using the Insulation layers in a door blank, reference is made to the explanations of the corresponding features for the inlay and door blank. It is also noted that the features and developments described for the inlay and door blank are also to be understood as features and developments of the use of the insulating layers in the door blank and the inlay, so that reference is also made to the description of the inlay and door blank with regard to these features and developments. Conversely, the features and developments described for the use of the insulating layer also represent features and developments of the door blank and/or the inlay, so that reference is made to the respective descriptions of the use of the insulating layer for a description of these. The same applies to the description of the features of the door blank, which also represent features of the inlay and vice versa.

The object is also achieved by a method for producing an inlay according to claims 1 to 10 or claim 11, in which an adhesive with spacers is arranged between two mineral plates in each case, the spacers being oversized and the spacers being pressed when the mineral plates are pressed, in particular in a press, penetrate the mineral plates in sections, so that a gap is created between the pressed mineral plates.

When manufacturing doors, the outer thickness is particularly important, since doors have clearly defined outer dimensions. In this respect, the outer thickness of the inlay and the door blank is important. This problem is partially solved by calibrating the mineral plates on both sides and simultaneously leveling the surfaces of the mineral plates (e.g. sanding with a wide-belt sander) of the individual layers, which, however, is expensive due to the time required and the machine costs incurred. The inventive method enables a particularly simple production of mineral plates arranged at a distance from one another, in which the outer thickness of the connected mineral plates (sandwich plates/multi-layer middle layer) can be adjusted particularly precisely without the need for calibration and equalization of the mineral plates on both sides. In the inventive method, differences in strength in the mineral plates and unevenness in the surface are compensated by the penetration depth of the spacers in the mineral plates, so that each external mineral plates only on one side, internal mineral plates, so mineral plates between two other mineral tiles (at least three-layer/three-ply structure) do not have to be calibrated and leveled. An oversize is understood to mean a thickness that is larger than the gap to be expected between the two mineral plates.

Fig. 1a bis 1d

schematisch Querschnitte unterschiedlicher Türrohlinge mit Inlay;

Fig. 2a bis 2d

schematisch unterschiedliche geeignete Auftragsmuster für Klebemittel zum Verkleben der Dämmlage mit der Mittellage;

Fig. 3

schematisch in einem Querschnitt ein Inlay zum Herstellen von Türen, mit einer Sandwichplatte, die mindestens zwei Lagen aufweist, wobei die Lagen jeweils abschnittsweise mit einem Klebemittel verbunden sind;

Fig. 4

das Inlay aus Figur 3, schematisch in einer Ansicht eine Mittellage mit aufgetragenem Klebemittel zum Verbinden mit einer Außenlage;

Fig. 5

schematisch ein Klebemittelauftragsmuster;

Fig. 6

schematisch ein weiteres Klebemittelauftragsmuster;

Tab. 1

eine tabellarische Übersicht bevorzugter Türrohlinge mit Inlay und deren Schichtaufbau;

Tab. 2

eine weitere tabellarische Übersicht bevorzugter Türrohlinge mit Inlay und deren Schichtaufbau;

The invention is explained in more detail below using a number of exemplary embodiments. Show it

Figures 1a to 1d

schematic cross-sections of different door blanks with inlay;

Figures 2a to 2d

Schematic of different suitable application patterns for adhesives for gluing the insulation layer to the middle layer;

3

schematically, in a cross section, an inlay for the manufacture of doors, with a sandwich panel which has at least two layers, the layers each being connected in sections with an adhesive;

4

the inlay off figure 3 12, schematically in a view, a middle layer with applied adhesive for connecting to an outer layer;

figure 5

schematically an adhesive application pattern;

6

schematically another adhesive application pattern;

Table 1

a tabular overview of preferred door blanks with inlay and their layer structure;

Table 2

another tabular overview of preferred door blanks with inlay and their layer structure;

Figure 1a shows a schematic cross-sectional representation of a first door blank 1 with an inlay 11 that includes a sandwich panel 2 that has a middle layer 3 with two opposite main surfaces 7 . Adjoining insulating layers 4 with soft surfaces 9 are arranged on both sides of the main surfaces 7 of the middle layer 3 . In addition, the outer layer 5 with a hard surface 8 is arranged adjacent to the soft surfaces 9 of each insulating layer 4 and on the side opposite the middle layer 3 . In the Figure 1a The outer layers 5 shown can alternatively also have a decorative outer side and can thus be designed as cover sides 12 . Also shown is a frame 6 belonging to the inlay 11, shown here as a piece of wood that the middle layer 3 and the insulating layer 4 encloses on all sides and to which the outer layers 5 are connected with their outer sections 5a, here they are glued.

The insulation layers 4 are connected in sections to the middle layer 3, here using adhesive dots 10 (see Fig Figure 2a to 2d ) glued together in sections. The arrangement of the adhesive dots 10 can be as shown in Figures 2a to 2d be executed, is here according to the Figure 2a executed. The outer layers 5 are each fully bonded to the insulating layer 4, but can alternatively also be used in sections (e.g. according to Figures 2a-2d -) be glued.

The Figure 1b shows a second preferred structural design of the inventive door blank 1 with an inlay 11 . The outer layers 5 thus jump back in relation to a cover side 12, here by the thickness of the frame 6. The cover sides 12 are arranged in addition to the outer layers 5. The cover pages 12 are already part of a finished door (not shown here). Each top side 12 is glued to an outer side 5 over its entire surface. The cover pages 12 fold out in accordance with the outer layers 5 Figure 1a on the frame 6 and are connected to it here.

The outer layers 5 have a density of at least 900 kg/m ³ and can be made of metal or HDF, for example, but are present here as HF plates. HF and HDF preferably have a density of 950 kg/m ³ to 1050 kg/m ³ . The outer layers 5 made of HDF and HF can have a thickness of between 3 mm and 7 mm and are designed here as plates with a thickness of approx. 3 mm. The outer layers 5 can be connected, for example glued, to the respective adjoining insulating layer 4 at least in sections, but here they are--as already mentioned--glued to the respective insulating layer 4 over their entire surface.

The middle layer 3 can be formed by means of a board with a low density in the range from 160 kg/m ³ to 450 kg/m ³ and is here a flax fiber board with a density of 350 kg/m ³ +/- 15 kg/m ³ . The flax fiber board can, as here, be designed as a one-piece board, or it can consist of several boards glued over the entire surface, for example. The middle layer 3 has a minimum thickness of 25 mm, here one thickness of 27 mm.

The insulating layer 4 is a plastic-based, soft and permanently elastic mat that has soft surfaces 9 compared to the surfaces 8 of the outer layers 5 designed as a plate. It should be noted that, for example, when using a HF plate with a screen-printed surface on one side as the outer layer 5, only the outer surface 8 of the HF plate has to be hard compared to the surfaces 9 of the insulating layer 4. The insulating layer 4 has a minimum density of 1,100 kg/m and is preferably designed as a plastic-based mat filled with a filler, in particular chalk or sand. The plastic acts as a binder. A PU-based insulating layer 4 has special soundproofing properties, in particular an insulating layer 4 with a polyurethane produced from a renewable raw material. The insulating layers 4 shown here are based on polyurethane with a density of over 1,250 kg/m ³ .

Figure 1C shows another alternative door blank 1 with an inlay 11. The door blank 1 is made according to the door blank 1 Figure 1a constructed, with the difference that the middle layer 3 is constructed from two individual interconnected plates 3a. The two plates 3a are spaced apart from one another but firmly connected to one another. The distance between the two plates is preferably between about 0.1 mm and 1 mm, here 0.1 mm. A plurality of spacers 13 are arranged to create the distance, so that an air gap 14 is formed between the plates 3a. The spacers 13 are formed here from a thin layer of wood the size of the adhesive dots. The spacers 13 are glued to the two plates 3a on both sides. The plates 3a are corresponding to the middle layer 3 from the Figure 1C educated. Alternatively, the two panels 3a can also be glued over their entire surface, especially when using soft fiber panels or flax panels.

Figure 1d shows another alternative door blank 1 with an inlay 11. The door blank 1 is made according to the door blank 1 Figure 1b constructed, with the difference that the middle layer 3 is constructed from two individual interconnected plates 3a. The two-layer structure of the middle layer 3 takes place in accordance with the middle layer 3 Figure 1c .

Figure 2a to 2d show different application patterns of adhesive, here adhesive points 10 between insulating layer 4 and middle layer 3. The adhesive is in particular designed to be permanently elastic. Figure 2a shows a distribution of 4-6 (large) adhesive dots 10 per 1 m ² middle layer 3, each with an adhesive surface between approx. 55 cm ² and approx. 114 cm ² , while FIG Figure 2d 20-28 (small) adhesive dots per 1 m ² middle layer 3 each with an adhesive area of between approx. 0.77 cm ² and approx. 7.1 cm ² . The Figures 2b and 2c show combinations of the Figures 2a and 2d each with large and small adhesive dots 10, in which the sound insulation values of over 42 db are achieved in combination with the claimed insulation layer 4, the middle layer 3 and, if necessary, the outer layers 5.

A particularly good soundproofing is achieved in the distribution of the adhesive points 10 Figure 2a to 2d achieved by arranging the dots of adhesive in rows and columns as shown. When distributing after Figure 1a the soundproofing is further improved in that the distances between the adhesive points 10 to one another and the distances between the two outer adhesive points 10 in a line and the adjacent outer sides are as equal as possible. The same applies to the distances between the adhesive points 10 of the columns. The adhesive points 10 can be formed, for example, as polygonal adhesive points 10 or in the form of lines. However, as shown, they are preferably arranged as round or at least largely round adhesive dots 10 .

figure 3 shows schematically in a cross section an inlay 11 with three layers 3, 5, a middle layer 3 and spaced apart from the middle layer 3 and arranged on opposite sides in each case an outer layer 5. Between the middle layer 3 and the respective outer layer 5 there is a gap, here an air gap 14 is arranged. The middle layer 3 is connected to the outer layers 5 in sections. For this purpose, an adhesive 10.1 is arranged in sections between the middle layer 3 and the respective outer layer 5. Spacers 13 are arranged between the middle layer 3 and the respective outer layer 5 in order to form the thickness of the gap particularly precisely. As a result, the distance (i.e. also the gap) between the respective mutually facing surfaces 8 of the middle layer 3 and outer layer 5 is homogeneously large over the entire surface of the middle layer 3 and outer layers 5. The gaps here are precisely 1 mm thick. The middle layer 3 and the outer layers 5 are made of identical mineral plates, each with a thickness of 19.3 mm +/-1 mm and a density of 400 kg/m ³ +/-20 kg/m ³ . To achieve the precise thickness, the mineral plates can be ground to size, for example on one or both sides. The inlay 11 thus has a largely precise thickness of 59.9 mm.

The mineral plates 16 are mineral fiber plates containing mineral fibers connected with a binder. The spacers 11 are made of the same material as the layers 3, 5 of the inlay 11 in order to improve recyclability, and are distributed as uniformly as possible over the surface of the respective middle layer 3 in order to ensure the most homogeneous gap thicknesses possible. The adhesive 10.1 is based on water glass, cyanoacrylate, isocyanate or polyurethane and ensures secure bonding of the mineral tiles.

figure 4 shows schematically in a view one side of a layers 3, 5 from figure 3 with applied adhesive 10.1. It is clearly visible that the adhesive 10.1 is applied in linear strips of adhesive. Adhesive strips are arranged in the area of the outer edges 15 (long side edges and short side edges) and additionally aligned diagonally to the outer edges 15 . Here the diagonal strips of adhesive were also arranged to each extend between two outer edges 15 . The angle of the diagonal adhesive strips 10.1 is preferably 45°, but here 30° to the long sides 15 and 60° to the short sides 15.

figure 5 shows an adhesive application pattern between two mineral panels or between two layers of a middle layer that is suitable for producing the high sound insulation values. If necessary, it would also be possible to glue an insulation layer to a mineral plate or layer of a middle layer. figure 5 shows the surface 8 of a mineral plate 16 for an inlay 11 as o approx. 1.0 m to 1.40 m wide and approx. 1.70 to 2.5 m high. The adhesive strips 10.1 are arranged parallel to the short and long sides 18, 19 of the mineral plate 16 as square frames 17.1 to 17.3. In this case, three frames 17.1 to 17.3 are arranged, which become smaller from the outside to the inside. Each adhesive frame 17.1 consists of adhesive strips 10.1 which are interrupted so that each Adhesive frame 17.1 to 17.3 is constructed from separate adhesive strip sections 20. The adhesive strip sections 20 of the outer adhesive frame 17.1 are offset to the adhesive strip sections 20 of the inwardly following adhesive frame 17.1. Inside the inner adhesive frame 17.3, two parallel adhesive strips 20 on the long side and one parallel adhesive strip 20 on the short side are arranged alternately, with three parallel adhesive strip sections 20 and two individual adhesive strip sections 20 being shown here.

The special advantage of this solution is a very small application of adhesive and the possibility of being able to individually reduce the width and length of the panels without them falling apart.

figure 6 12 shows another suitable adhesive application pattern between two mineral plates 16 or between two layers of a middle layer 3 (not shown here), with which high sound insulation values can be achieved. A mineral plate 16 in size for an inlay 11 is shown again (see figure 5 ). Nine adhesive dots 10 are applied to the mineral plate 16 here. The nine adhesive points 10 largely correspond to the design in terms of their distribution and size Figure 2a . In addition, in particular for easy handling of the sandwich made of two mineral plates 16 or two layers of a middle layer 3, an adhesive frame 17.1 made of a very narrow adhesive strip 10.1 is arranged in the area of the outer edges 15.

Table 1 with a first tabular overview shows 6 (No. 1 to No. 6) particularly preferred embodiments of the door blank 1 (middle layer+insulating layers+outer layers) with inlay 11 (middle layer+insulating layers). All variants shown achieve a sound insulation value of 42 db, measured according to DIN EN ISO 10140-2. Table 1 middle position insulation layers outer layers Bonding middle layer insulation layer No material minimum strength density material minimum strength density material minimum strength density mm kg/ ^m3 mm kg/ ^m3 mm kg/ ^m3 accordingly Figure 2a, 2b, 2c or 2d 1 FFP 27 about 350 Ku/PU 2-3 about 1.25 HF about 3 >900 accordingly Figure 2a, 2b, 2c or 2d 2 FFP 37 about 350 Ku/PU 3-4 HF about 3 >900 accordingly Figure 2a, 2b, 2c or 2d 3 FFP 33 about 350 Ku/PU 2-3 about 1.25 HF about 3 >900 accordingly Figure 2a, 2b, 2c or 2d 4 FFP 33 about 350 Ku/PU 3-4 HF about 3 >900 accordingly Figure 2a, 2b, 2c or 2d 5 FFP 33 about 350 Ku/PU 4-5 about 1.4 HF about 3 >900 accordingly Figure 2a, 2b, 2c or 2d 6 FFP 27 about 350 Ku/PU 2-3 about 1.25 HF approx. 6 (2×3 per outer layer) >900 accordingly Figure 2a, 2b, 2c or 2d

The abbreviations FFP mean: flax fiber board, Ku: plastic-based, PU: polyurethane-based and HF: hard fiber board. In the exemplary embodiments, the insulating layer 4 is preferably bonded to the respective outer layer 5 over the entire surface. With gluing in sections, the sound insulation values can be further increased. Metal plates with a lower thickness of at least 1 mm can be used as outer layers instead of or in addition to the hard fiber board. The structural design of the listed examples 1 to 5 takes place accordingly figure 1 , corresponding to example 6 Fig. 1b ..

Table 2 with a second tabular overview shows 21 (No. 7 to No. 27) further preferred embodiments of the inlay 11. Table 2 No. Insulation layer thickness in mm Bonding insulation layer middle layer Middle layer strength, material, density Gluing the middle layers Middle layer strength, material, density Bonding insulation layer middle layer Insulation layer thickness in mm 7 2 KMP: 4-6 m ² Diameter: 10cm 60mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 2 8th 3 KMP: 4-6 m ² Diameter: 10cm 29mm, flax, 350kg/ ^m3 flat glued 29mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 9 4 KMP: 4-6 m ² Diameter: 10cm 28mm, flax, 350kg/ ^m3 flat glued 28mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 4 10 3 KMP: 4-6 m ² Diameter: 10cm 36mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 11 4 KMP: 4-6 m ² Diameter: 10cm 34mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 4 12 3 KMP: 4-6 m ² Diameter: 10cm 28mm, flat,s 350kg/m ³ Permanently elastic distance min. 0.6 28mm, flat,s 350kg/m ³ KMP: 4-6 m ² Diameter: 10cm 3 13 4 KMP: 4-6 m ² Diameter: 10cm 28mm, flax, 350kg/ ^m3 Permanently elastic distance min. 0.6 28mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 4 14 3 KMP: 4-6 m ² Diameter: 10cm 28mm, flax, 350kg/ ^m3 flat glued 28mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 15 3 KMP: 4-6 m ² Diameter: 10cm 34mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 16 4 KMP: 4-6 m ² Diameter: 10cm 32mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 4 17 4 Fig. 2d 32mm flax 350kg/ ^m3 Fig. 2d 4 18 4 KMP: 4-6 m ² Diameter: 10cm 28mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 4 19 3 KMP: 4-6 m ² Diameter: 10cm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² diameter: 10cm spacing about 0.8mm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 20 3 KMP: 4-6 m ² Diameter: 10cm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² diameter: 10cm spacing about 0.8mm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3 21 2 KMP: 4-6 m ² Diameter: 10cm 28mm, flax, 350kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 2 22 3 Figure 2b 32mm, flax, 350kg/ ^m3 Figure 2b 3 23 3 Figure 2c 32mm, flax, 350kg/ ^m3 Figure 2c 3 24 3 Fig. 2d 32mm, flax, 350kg/ ^m3 Fig. 2d 3 25 3 KMP: 4-6 m ² Diameter: 10cm 34 mm tubular chip type KMP: 4-6 m ² Diameter: 10cm 3 26 3 KMP: 4-6 m ² Diameter: 10cm 15mm, soft fiber, 2.50kg/m3 KMP: 4-6 m ² Diameter: 10cm 15mm, soft fiber, 250kg/m3 KMP: 4-6 m ² Diameter: 10cm 3 27 3 KMP: 4-6 m ² Diameter: 10cm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm MFP, 20mm, 380kg/ ^m3 KMP: 4-6 m ² Diameter: 10cm 3

All variants shown achieve a sound insulation value of 42 db either on their own or at least in combination with two outer layers of fiberboard (HDF, HF) with a hard surface and a density of at least 900 kg/m ³ that are glued to the insulation layers over the entire surface 42 db, measured according to DIN EN ISO 10140-2. The abbreviations KMP mean: adhesive center; 4-6 m ² : four to six adhesive points per m ² ; Diameter 10 cm: diameter of the adhesive center point about 10 cm; Flax: flax fiber board; MFP: mineral fiber board; Permanently elastic: Permanently elastic adhesive; Spacing: distance between middle layers; Soft fibre: soft fibreboard, in particular made of wood fibres.

The insulating layers 4 used all have a density of approximately 1,250 kg/m ³ , but can alternatively have a density in particular in the range from 1,250 kg/m ³ to 1,500 kg/m ³ . The surfaces of the insulating layers 4 are soft. They have a reinforcement layer, here a PE fleece, which is aligned in the direction of the middle layer. Alternatively, both surfaces of the insulating layers 4 can also be coated with a reinforcement layer, in particular a PE fleece. In addition to the actual reinforcement of the surfaces, the reinforcement layer improves adhesion. PE nonwovens in particular make it easy to glue with normal white glue (PVAC glue).

In the inlays 11 of the exemplary embodiments 7, 10, 11, 15 to 18 and 21 to 25, the middle layer 3 is constructed from a one-piece plate, while in the other exemplary embodiments 8, 9, 12 to 14, 19, 20, 26 and 27 a two-layer structure of the middle layer 3 is present. The exemplary embodiments 8, 9 and 14 have boards glued flat as the middle layer 3, the middle layers 3 of exemplary embodiments 12 and 13 are glued with a corresponding spacing Figure 1a , the middle layers 3 of the exemplary embodiments 19, 20, and 26 are without spacing but also only at certain points according to the gluing pattern Figure 1a tied together.

With the exception of the exemplary embodiments 17, 22, 23 and 24, the insulating layers 4 and middle layers 3 of all inlays 11 follow the same pattern as the glue Figure 1a glued. Alternatively, however, the insulating layers 4 and middle layers 3 can also be made according to one of the glue patterns Figures 1b to 1d be glued.

The exemplary embodiments 25 and 26 in particular are designed differently. It has been shown that middle layers 3 made of tubular chipboard, which have a density in the inventive range, can be used as middle layers 3 in order to achieve sufficient soundproofing in combination with the soft insulation layers. The same applies to 2 approx. 15 mm thick soft fiber boards (especially made of wood fibers) with a density of approx. 250 kg/m ³ , which are glued over the entire surface or, as here, in sections, can be used as a middle layer 3 in combination with the soft insulating layers 4. Some of the insulation layers 4 listed here are only 2 or 3 mm thick. In principle, insulating layers of 4 mm or, as with all inlays 11, of more than 4 mm can also be used here in order to ensure the necessary soundproofing, but this often means that specifications for the thickness of the subsequent door thickness are exceeded.

It remains to be noted that the inlays 11 and door blanks 1 listed in Table 1 and the inlays 11 listed in Table 2 can all be used in combination with corresponding outer layers 5, which have a minimum density of 950 kg/m ³ and in particular as HDF or HF are designed with a thickness of at least 3 mm, are suitable for ensuring corresponding sound insulation values of 42 db for interior doors and apartment entrance doors with standard thicknesses and weights.

Reference List

1

door blank

2

sandwich panel

3

middle position

3a

plates

4

insulation layer

5

outer layer

5a

outer sections

6

Frame

7

main surfaces

8th

surface

9

surface

10

adhesive center points

10.1

adhesive strips

11

inlay

12

cover pages

13

spacers

14

air gap

15

outer edge

16

mineral plate

17.1

Frame adhesive strips

17.2

Frame adhesive strips

17.3

Frame adhesive strips

17

Short page

18

long sides

19

adhesive strip sections

Claims (15)

Inlay for the production of doors, with a sandwich panel (2) which has at least two layers, the layers each being connected in sections with an adhesive (10, 10.1),
characterized in that - the layers are mineral plates (16), - the mineral plates (16) have a density of 340 kg/m ³ to 420 kg/m ³ , in particular 380 kg/m ³ to 420 kg/m ³ and a thickness of 15 mm to 31 mm, in particular 20 mm +/- 1 mm, - and between the layers there is a gap with a thickness of 0.4 mm to 3 mm, in particular between 0.5 mm and 2 mm. Inlay according to Claim 1, characterized in that the sandwich panel (2) is constructed in at least three layers, with a middle layer (3) and outer layers (5) arranged on opposite sides of the middle layer (3). Inlay according to one of the preceding claims, characterized in that the layers are glued together in sections. Inlay according to one of the preceding claims, characterized in that the gap between the respective layers is formed by means of a correspondingly strong adhesive (10, 10.1) and/or in that spacers (13) are arranged between the layers. Inlay according to Claim 4, characterized in that the spacers (13) consist of the material of the mineral plates and/or comprise perlite. Inlay according to one of the preceding claims, that the adhesive comprises water glass, polyurethane, cyanoacrylate, isocyanate. Inlay according to one of the preceding claims, characterized in that the adhesive (10, 10.1) is arranged in the area of the outer edges (15) of the layers and as adhesive strips (10.1) extending diagonally to the outer edges (15) of the layers. Inlay according to one of the preceding claims, characterized in that the inlay (11) in a door has a sound insulation value of at least 42 db measured according to EN ISO 10140-2 and/or a fire resistance EI 30 measured according to EN 1634-1. Door for use as interior doors, apartment entrance doors and/or exterior doors with an inlay (11) according to Claims 1 to 8. Inlay for a door blank (1) for the production of interior doors and apartment entrance doors, with a sandwich panel (2) having at least one middle layer (3) made of a panel with two opposite main surfaces (7) and on each of the main surfaces (7) of the middle layer (3) in each case at least one adjacent further sandwich layer, characterized in that - the middle layer (3) has a thickness of at least 20 mm and - has a density between 160 kg/m ³ and 450 kg/m ³ , and - the sandwich layers arranged on the middle layer (3) are connected in sections to the middle layer (3) and each as a soft insulating layer (4) made of a permanently elastic material, in particular based on plastic with a thickness of between 2 mm and 6 mm and a density of between 1,100 kg/ m ³ and 1,800 kg/m ³ are formed. Door blank with an inlay according to one of the preceding claims, characterized in that the sandwich panel (2) is connected to hard outer layers (5) to form the door blank (1), the outer layers (4) having a density of at least 900 kg/m ³ and the surfaces (8) of the outer layers (5) are hard against the soft surface (9) of the insulating layers (4) or the mineral plates (16). Door for use as an interior door or apartment entrance door with an inlay (11) according to at least one of Claims 1 to 8 or 10. Door for use as an interior door or apartment entrance door with a door blank (1) according to Claim 11. Use of at least two insulating layers, each approx. 2 mm to approx. 6 mm thick, made of (3) a permanently elastic material, in particular based on plastic, in particular polyurethane with a density between 1150 kg/m ³ and 1800 kg/m ³ in an inlay (11) for a door blank (1) for producing interior doors and apartment entrance doors, with a sandwich panel (2) which has a middle layer (3) made from at least one panel with a density between 160 kg/m ³ and 450 kg/m ³ . Method for producing an inlay (11) according to claim 1 to 9 or claim 10, characterized in that an adhesive with spacers (13) is arranged between two mineral plates (16) in each case, the spacers (13) having an oversize and the spacers (13) when the mineral plates (16) are pressed, in particular in a press, penetrate in sections into the mineral plates (16) so that a gap is formed between the pressed mineral plates (16).

Images