Multi-layered fire door and method for making the same

• US 7,721,500 B2
• Filed: 01/23/2007
• Issued: 05/25/2010
• Est. Priority Date: 10/31/2002
• Status: Expired due to Term

• Current Assignee: JELD-WEN Incorporated (JELD-WEN Holding, Inc.)
• Original Assignee: JELD-WEN Incorporated (JELD-WEN Holding, Inc.)
• Inventors: Lewallen, Keith Lynn, Olson, Brent David, Koepke, Gary Lee, Transue, William Robert, Clark, Randy Jon
• Primary Examiner(s): Chilcot, Jr.; Richard E
• Assistant Examiner(s): Nguyen; Chi Q
• Application Number:
  US11/656,628
• Publication Number:
  US 20070125044A1
• Time in Patent Office: 1,218 Days
• Field of Search: 524/55, 527/941, 522/054, 522/10, 527/841.1, 527/831.3, 522/32, 527/841, 527/841.5, 523/099, 428/318.4, 428/532, 495/01
• US Class Current: 52/455
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2325/00 Polymers of vinyl-aromatic compounds, e.g. polystyrene
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/942 slab-shaped
• CPC Class Codes: E06B 2003/7023 of foam type
• CPC Class Codes: E06B 2003/7025 of cork; of wood or similar fibres
• CPC Class Codes: E06B 3/7001 Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
• CPC Class Codes: E06B 5/16 Fireproof doors or similar closures; Adaptations of fixed constructions therefor

Abstract

A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.

Claims

1. A door comprising:

a porous layer having two opposing major surfaces;

at least three fire-retardant layers each comprising a fiberboard and coupled with the porous layer in an unbalanced construction, wherein a number of the at least three fire-retardant layers disposed on one of the two opposing major surfaces of the porous layer is greater than a number of the at least three fire-retardant layers disposed on another one of the two opposing major surfaces of the porous layer;

a first exterior layer; and

a second exterior layer, wherein the first exterior layer is coupled with one of the at least three fire retardant layers and the second exterior layer is coupled with another one of the at least three fire-retardant layers.

2. The door according to claim 1, wherein a density of the porous layer is at least one pound per cubic foot.

3. The door according to claim 1, wherein a thickness of each of the at least three fire-retardant layers is about the same.

4. The door according to claim 3, wherein the thickness of each of the at least three fire-retardant layers is about three-eights of an inch.

5. The door according to claim 3, wherein a thickness of the porous layer is about the same as the thickness of each of the at least three fire-retardant layers.

6. The door according to claim 5, wherein the thickness of the porous layer is about three-eights of an inch.

7. The door according to claim 1, wherein the porous layer comprises a thermoplastic polymer having a density of about one pound per cubic foot.

8. The door according to claim 1, wherein the porous layer comprises a fire-retardant material.

9. The door according to claim 1, wherein the fiberboard comprises a medium-density fiberboard.

10. The door according to claim 9, wherein a density of the medium-density fiberboard is at least 42 pounds per cubic foot.

11. The door according to claim 1, wherein a thickness of the first exterior layer is about the same as a thickness of the second exterior layer.

12. The door according to claim 11, wherein the thickness of the first exterior layer is about one-eighth of an inch.

13. The door according to claim 1, wherein each of the first and second exterior layers comprises a hard board.

14. The door according to claim 13, wherein a density of the hardboard is at least 52 pounds per cubic foot.

15. The door according to claim 1, further comprising a grooved first pattern disposed on the first exterior layer and having a first depth and a grooved second pattern disposed on the second exterior layer and having a second depth, wherein the first depth penetrates a thickness of the first exterior layer and a portion of a thickness of one of the at least three fire-retardant layers.

16. The door according to claim 15, wherein the second depth penetrates a thickness of the second exterior layer and a portion of a thickness of the another one of the at least three fire-retardant layers.

17. The door according to claim 16, wherein the first and second depths are about the same.