FIRE RATED DOOR CORE
A core for a fire rated door includes a fire resistant center panel and an extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made of a first fire resistant material. The extruded fire resistant border is attached to the first side, the second side, the first end and the second end of the fire resistant center panel. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.
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This patent application is related to U.S. patent application Ser. No. ______ filed on Jun. 29, 2012 and entitled “Fire Rated Door”, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTIONThe present invention relates generally to the field of door manufacturing and, more particularly, to a fire rated door core.
BACKGROUND OF THE INVENTIONMany methods and techniques for manufacturing fire rated doors have been developed over time. But most of these prior art designs do not lend themselves well to fully automated manufacturing processes. Moreover, the prior art fire rated doors are expensive and require the internal mineral core. The internal core can be exposed in routed details and may reduce the strength of the door as a result of the reduced thickness of the door panels. In addition, alignment of the panels during assembly can be troublesome and require additional finishing to square the door after assembly. As a result, there is a need for a fire rated door that does not suffer from these deficiencies.
SUMMARY OF THE INVENTIONThe door core of the present invention provides the fire resistant capabilities necessary to receive the necessary fire certifications. In most cases, the length and width of the fire rated door core will match the length and width specifications of the final door product. The dimensions of the fire rated door core will typically be in widths of three feet and four feet and having a length ranging from seven feet to ten feet. The thickness of the fire core can range from 1.50 inches to 2.00 inches. In some cases, an exterior banding may be added to the sides and ends of the fire rated door core. In other cases, an intumescent banding may be added between the exterior banding and fire rated door core.
More specifically, the present invention provides a core for a fire rated door that includes a fire resistant center panel and an extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made of a first fire resistant material. The extruded fire resistant border is attached to the first side, the second side, the first end and the second end of the fire resistant center panel. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.
In addition, the present invention provides a method of manufacturing a core for a fire rated door by providing a fire resistant center panel, attaching a first stile of an extruded fire resistant border to the first side of the fire resistant center panel, attaching a second stile of the extruded fire resistant border to the second side of the fire resistant center panel, attaching a first rail of the extruded fire resistant border to the first end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border, and attaching a second rail of the extruded fire resistant border to the second end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made of a first fire resistant material. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.
Moreover, the present invention provides a method of manufacturing a core for a fire rated door by providing an extruded fire resistant border having a central void, filling the void within the extruded fire resistant border with a first fire resistant material that has a lower density than the second fire resistant material to form a fire resistant center panel, and baking the extruded fire resistant border and first fire resistant material. The extruded fire resistant border is provided by providing a first stile of the extruded fire resistant border, attaching a first rail of the extruded fire resistant border to the first stile of the extruded fire resistant border, attaching a second rail of the extruded fire resistant border to the first stile, and attaching a second stile of the extruded fire resistant border to the first rail and the second rail of the extruded fire resistant border. The extruded fire resistant border is made of a second fire resistant material.
The present invention is described in detail below with reference to the accompanying drawings.
The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which:
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention. The discussion herein relates primarily to fire rated doors, but it will be understood that the concepts of the present invention are applicable to any type of door.
The door core of the present invention provides the fire resistant capabilities necessary to receive the necessary certification. The length and width of the fire core will match the length and width specifications of the final door product. The dimensions of the fire core will typically be in widths of three feet and four feet and having a length ranging from seven feet to ten feet. The thickness of the door core will typically be between 0.125″ and 1.5″. A door manufacturer can use any of the completed core designs described herein as the fire resistant core of the manufacturer's fire-rated door. The resulting fire rated door can have fire ratings of 20-30, 45, 60, 90 or 120 minutes depending on the configuration and materials used. The manufacturer will typically finish the final door product by adding a final piece of wood or veneer to the door to provide the aesthetic appeal of the product.
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In one embodiment, a notch is formed in the first side of the fire resistant center panel, a fire resistant lock block is inserted within the notch and the fire resistant lock block is attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material. In another embodiment, the fire resistant center panel includes: (a) a first fire resistant center panel disposed between the first side and the second side proximate to the first end, wherein the first fire resistant center panel is made of the first fire resistant material; (b) a second fire resistant center panel disposed between the first side and the second side proximate to the second end, wherein the second fire resistant center panel is made of the first fire resistant material; and (c) a fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made of the second fire resistant material. In yet another embodiment, a set of male-female connectors are formed in the extruded fire resistant border and the fire resistant center panel. The male-female connectors can be triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.
In another embodiment, the first fire resistant material is extruded or molded to form the fire resistant center panel, and the second fire resistant material is extruded or molded to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border. In yet another embodiment, the first fire resistant material is extruded or molded to form the fire resistant center panel, and the second fire resistant material is extruded or molded to form a sheet that is then gang ripped to form one or more of the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border. In either embodiment the panels, stiles and rails may undergo one or more finishing steps (e.g., sanding, trimming, cutting, denibbing, etc.) so that the pieces have the proper smoothness, size and shape.
Furthermore, a top panel can be attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom panel can be attached to the bottom of the fire resistant center panel, or both the top panel and the bottom panel can be attached to the fire resistant center panel. The top panel or the bottom panel can be a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof. The one or more protective layers can be a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof. For example, the one or more protective layers can be one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.
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In one embodiment, a notch is formed in the first side of the fire resistant center panel, a fire resistant lock block is inserted within the notch and the fire resistant lock block is attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material. In another embodiment, the fire resistant center panel includes: (a) a first fire resistant center panel disposed between the first side and the second side proximate to the first end, wherein the first fire resistant center panel is made of the first fire resistant material; (b) a second fire resistant center panel disposed between the first side and the second side proximate to the second end, wherein the second fire resistant center panel is made of the first fire resistant material; and (c) a fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made of the second fire resistant material. In yet another embodiment, a set of male-female connectors are formed in the extruded fire resistant border and the fire resistant center panel. The male-female connectors can be triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.
In another embodiment, the first fire resistant material is extruded or molded to form the fire resistant center panel, and the second fire resistant material is extruded or molded to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border. In yet another embodiment, the first fire resistant material is extruded or molded to form the fire resistant center panel, and the second fire resistant material is extruded or molded to form a sheet that is then gang ripped to form one or more of the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border.
Furthermore, a top panel can be attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom panel can be attached to the bottom of the fire resistant center panel, or both the top panel and the bottom panel can be attached to the fire resistant center panel. The top panel or the bottom panel can be a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof. The one or more protective layers can be a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof. For example, the one or more protective layers can be one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.
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Claims
1. A core for a fire rated door comprising:
- a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material; and
- an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.
2. The core as recited in claim 1, further comprising:
- a notch in the first side of the fire resistant center panel; and
- a fire resistant lock block disposed within the notch and attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.
3. The core as recited in claim 1, wherein the fire resistant center panel comprises:
- a first fire resistant panel made of the first fire resistant material;
- a second fire resistant panel made of the first fire resistant material; and
- an extruded fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made of the second fire resistant material.
4. The core as recited in claim 1, wherein the extruded fire resistant border is attached to the fire resistant center panel with a set of male-female connectors formed in the extruded fire resistant border and the fire resistant center panel.
5. The core as recited in claim 4, wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.
6. The core as recited in claim 1, wherein the first fire resistant material is extruded or molded.
7. The core as recited in claim 1, wherein the extruded fire resistant border is assembled and the fire resistant center panel is poured and set within the extruded fire resistant border.
8. The core as recited in claim 1, wherein the extruded fire resistant border comprises:
- a first stile;
- a second stile;
- a first rail attached to the first stile and the second stile; and
- a second rail attached to the first stile and the second stile.
9. The core as recited in claim 1, further comprising a top panel attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom panel attached to the bottom of the fire resistant center panel, or both the top panel and the bottom panel.
10. The core as recited in claim 10, wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.
11. The core as recited in claim 11, wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.
12. The core as recited in claim 11, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.
13. The core as recited in claim 1, wherein the fire resistant center panel and the extruded fire resistant border are coated with an intumescent or fire resistant material.
14. The core as recited in claim 1, wherein the first fire resistant material and the second fire resistant material are composed of water, gypsum, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents.
15. The core as recited in claim 1, wherein the fire resistant center panel comprises:
- a center panel made of the first fire resistant material or the second fire resistant material;
- a top insulating panel attached to the top of the center panel; and
- a bottom insulating panel attached to the bottom of the center panel.
16. The core as recited in claim 15, wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.
17. A method of manufacturing a core for a fire rated door, comprising the steps of: attaching a second rail of the extruded fire resistant border to the second end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border.
- providing a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material;
- attaching a first stile of an extruded fire resistant border to the first side of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material;
- attaching a second stile of the extruded fire resistant border to the second side of the fire resistant center panel;
- attaching a first rail of the extruded fire resistant border to the first end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border; and
18. The method as recited in claim 17, further comprising the steps of:
- forming a notch in the first side of the fire resistant center panel; and
- inserting a fire resistant lock block within the notch and attaching the fire resistant lock block to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.
19. The method as recited in claim 17, wherein the fire resistant center panel comprises:
- a first fire resistant center panel disposed between the first side and the second side proximate to the first end, wherein the first fire resistant center panel is made of the first fire resistant material;
- a second fire resistant center panel disposed between the first side and the second side proximate to the second end, wherein the second fire resistant center panel is made of the first fire resistant material; and
- a fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made of the second fire resistant material.
20. The method as recited in claim 17, further comprising the step of forming a set of male-female connectors in the extruded fire resistant border and the fire resistant center panel.
21. The method as recited in claim 20, wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.
22. The method as recited in claim 17, further comprising the steps of:
- extruding or molding the first fire resistant material to form the fire resistant center panel; and
- extruding or molding the second fire resistant material to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border.
23. The method as recited in claim 17, further comprising the steps of:
- extruding or molding the first fire resistant material to form the fire resistant center panel; and
- extruding or molding the second fire resistant material to form a sheet, and gang ripping the sheet to form one or more of the first stile, the second stile, the first rail or the second rail of the extruded fire resistant border.
24. The method as recited in claim 17, further comprising the step of attaching a top panel to the top of the fire resistant center panel and the extruded fire resistant border, or attaching a bottom panel to the bottom of the fire resistant center panel, or attaching both the top panel and the bottom panel.
25. The method as recited in claim 24, wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.
26. The method as recited in claim 25, wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.
27. The method as recited in claim 25, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.
28. The method as recited in claim 17, further comprising the step of coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material.
29. The method as recited in claim 17, wherein the method is performed as part of a continuous manufacturing process.
30. The method as recited in claim 17, further comprising the step of forming a fire rated door by attaching a first decorative panel to a top of the core and attaching a second decorative panel to a bottom of the core.
31. The method as recited in claim 17, wherein the fire resistant center panel comprises:
- a center panel made of the first fire resistant material or the second fire resistant material;
- a top insulating panel attached to the top of the center panel; and
- a bottom insulating panel attached to the bottom of the center panel.
32. The method as recited in claim 31, wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.
33. A method of manufacturing a core for a fire rated door, comprising the steps of:
- providing an extruded fire resistant border having a central void by providing a first stile of the extruded fire resistant border, attaching a first rail of the extruded fire resistant border to the first stile of the extruded fire resistant border, attaching a second rail of the extruded fire resistant border to the first stile and attaching a second stile of the extruded fire resistant border to the first rail and the second rail of the extruded fire resistant border, wherein the extruded fire resistant border is made of a second fire resistant material;
- filling the void within the extruded fire resistant border with a first fire resistant material that has a lower density than the second fire resistant material to form a fire resistant center panel; and
- baking the extruded fire resistant border and first fire resistant material.
34. The method as recited in claim 33, further comprising the step of inserting a fire resistant lock block within the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.
35. The method as recited in claim 33, wherein the fire resistant center panel comprises:
- a first fire resistant center panel disposed between the first side and the second side proximate to the first end, wherein the first fire resistant center panel is made of the first fire resistant material;
- a second fire resistant center panel disposed between the first side and the second side proximate to the second end, wherein the second fire resistant center panel is made of the first fire resistant material; and
- a fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made of the second fire resistant material.
36. The method as recited in claim 33, further comprising the step of forming a set of male-female connectors in the extruded fire resistant border and the fire resistant center panel.
37. The method as recited in claim 36, wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.
38. The method as recited in claim 33, further comprising the steps of:
- extruding or molding the first fire resistant material to form the fire resistant center panel; and
- extruding or molding the second fire resistant material to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border.
39. The method as recited in claim 33, further comprising the steps of:
- extruding or molding the first fire resistant material to form the fire resistant center panel; and
- extruding or molding the second fire resistant material to form a sheet, and gang ripping the sheet to form one or more of the first stile, the second stile, the first rail or the second rail of the extruded fire resistant border.
40. The method as recited in claim 33, further comprising the step of attaching a top panel to the top of the fire resistant center panel and the extruded fire resistant border, or attaching a bottom panel to the bottom of the fire resistant center panel, or attaching both the top panel and the bottom panel.
41. The method as recited in claim 40, wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.
42. The method as recited in claim 41, wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.
43. The method as recited in claim 41, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.
44. The method as recited in claim 33, further comprising the step of coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material.
45. The method as recited in claim 33, wherein the method is performed as part of a continuous manufacturing process.
46. The method as recited in claim 33, wherein the first fire resistant material and the second fire resistant material are composed of water, gypsum, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents.
47. The method as recited in claim 33, further comprising the step of forming a fire rated door by attaching a first decorative panel to a top of the core and attaching a second decorative panel to a bottom of the core.
48. The method as recited in claim 33, wherein the fire resistant center panel comprises:
- a center panel made of the first fire resistant material or the second fire resistant material;
- a top insulating panel attached to the top of the center panel; and
- a bottom insulating panel attached to the bottom of the center panel.
49. The method as recited in claim 48, wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.
Type: Application
Filed: Jun 29, 2012
Publication Date: Jan 2, 2014
Applicant: 820 INDUSTRIAL LOOP PARTNERS LLC (Frisco, TX)
Inventors: Evan R. Daniels (Frisco, TX), Jonathan Newton (Dallas, TX)
Application Number: 13/538,788
International Classification: E06B 5/16 (20060101); B23P 11/00 (20060101); E04B 1/94 (20060101);