Fire rated door core

• US 8,881,494 B2
• Filed: 10/05/2012
• Issued: 11/11/2014
• Est. Priority Date: 10/11/2011
• Status: Active Grant

• Current Assignee: Polymer-Wood Technologies, Inc.
• Original Assignee: Polymer-Wood Technologies, Inc.
• Inventors: Daniels, Evan R., Newton, Jonathan, Ross, Ralph
• Primary Examiner(s): Nguyen, Chi Q
• Application Number:
  US13/646,292
• Publication Number:
  US 20130086858A1
• Time in Patent Office: 767 Days
• Field of Search: 524/56, 524/55, 527/841, 527/841.1, 523/091.5, 527/831.3, 527/831.2, 527/841.4, 522/32, 524/58, 524/57, 526/564, 428/373, 295/30
• US Class Current: 52/784.11
• CPC Class Codes: B23P 17/00 Metal-working operations, not covered by a single other subclass or another group in this subclass
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: E04C 1/40 built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
• CPC Class Codes: E06B 2003/7042 with a fire retardant layer
• CPC Class Codes: E06B 2003/7046 with provisions for locks, hinges or other fittings
• CPC Class Codes: E06B 2003/7051 of layered construction involving different materials
• CPC Class Codes: E06B 3/721 with panels on one lateral side of the frame only
• CPC Class Codes: E06B 3/82 Flush doors, i.e. with completely flat surface E06B3/02, E06B3/7003 and E06B3/7015 take precedence
• CPC Class Codes: E06B 5/16 Fireproof doors or similar closures; Adaptations of fixed constructions therefor
• CPC Class Codes: Y10T 29/49993 Filling of opening

Abstract

A core for a fire rated door includes an extruded fire resistant material, a filler material and a panel. The extruded fire resistant material has a first raised portion, a second raised portion and a lower portion that extends from a first end to a second end. The first raised portion has a first thickness and a first width that extends from the first side to the lower portion. The lower portion has a second thickness. The second raised portion has the first thickness and a second width that extends from the second side to the lower portion. The filler material is disposed above the lower portion of the extruded fire resistant material between the first raised portion and the second portion. The panel is attached to the first raised portion and the second raised portion of the extruded fire resistant material and covers the filler material.

Claims

1. A core for a fire rated door comprising:

an extruded fire resistant material having a bottom, a first side, a second side, a first end and a second end to form a first raised portion, a second raised portion and a single lower portion disposed between the first raised portion and the second raised portion, wherein;

(a) the first raised portion, the second raised portion and the single lower portion extend from the first end to the second end, (b) the first raised portion has a first thickness above the bottom and a first width that extends from the first side to the single lower portion, (c) the single lower portion has a second thickness above the bottom, (d) the second raised portion has the first thickness above the bottom and a second width that extends from the second side to the single lower portion, (e) the first width of the first raised portion is sufficient to accommodate a lockset, and (f) the second width of the second raised portion is sufficient to accommodate a set of door hinges;

a filler material having a third thickness disposed above the single lower portion of the extruded fire resistant material between the first raised portion and the second raised portion such that the sum of the second thickness and the third thickness is substantially equal to the first thickness; and

a single substantially flat panel attached to the first raised portion and the second raised portion of the extruded fire resistant material and covering the filler material.

2. The core as recited in claim 1, wherein the single substantially flat panel comprises a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic or a combination thereof.

3. The core as recited in claim 1, wherein the filler material comprises a styrene, a spray foam material, an extruded foam material or a protective layer.

4. The core as recited in claim 3, wherein the filler material comprises 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 or a combination thereof.

5. The core as recited in claim 3, wherein the filler material comprises a gypsum board, a metallic sheet, a lead sheet, a kevlar sheet, a ceramic sheet, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.

6. The core as recited in claim 1, wherein the extruded fire resistant material and single substantially flat panel are coated with an intumescent or fire resistant material.

7. A fire rated door comprising:

a core comprising;

(1) an extruded fire resistant material having a bottom, a first side, a second side, a first end and a second end to form a first raised portion, a second raised portion and a single lower portion disposed between the first raised portion and the second raised portion, wherein;

(a) the first raised portion, the second raised portion and the single lower portion extend from the first end to the second end, (b) the first raised portion has a first thickness above the bottom and a first width that extends from the first side to the single lower portion, (c) the single lower portion has a second thickness above the bottom, (d) the second raised portion has the first thickness above the bottom and a second width that extends from the second side to the single lower portion, (e) the first width of the first raised portion is sufficient to accommodate a lockset, and (f) the second width of the second raised portion is sufficient to accommodate a set of door hinges, (2) a filler material having a third thickness disposed above the single lower portion of the extruded fire resistant material between the first raised portion and the second portion such that the sum of the second thickness and the third thickness is substantially equal to the first thickness, and (3) a single substantially flat panel attached to the first raised portion and the second raised portion of the extruded fire resistant material and covering the filler material;

a first decorative panel attached to the single substantially flat panel of the core, the first decorative panel extending at least to the first side, the second side, the first end and the second end of the core; and

a second decorative panel attached to the bottom of the extruded fire resistant material, the second decorative panel extending at least to the first side, the second side, the first end and the second end of the core.

8. The fire rated door as recited in claim 7, further comprising an exterior banding attached to each side and end of the core.

9. The fire rated door as recited in claim 8, further comprising an intumescent banding material disposed between the exterior banding and the core.

10. The fire rated door as recited in claim 7, wherein the single substantially flat panel comprises a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic or a combination thereof or a combination thereof.

11. The fire rated door as recited in claim 7, wherein the filler material comprises a styrene, a spray foam, an extruded foam or a protective layer.

12. The fire rated door as recited in claim 11, wherein the filler material comprises 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 or a combination thereof.

13. The fire rated door as recited in claim 11, wherein the filler material comprises a gypsum board, a metallic sheet, a lead sheet, a kevlar sheet, a ceramic sheet, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.

14. The fire rated door as recited in claim 7, wherein the extruded fire resistant material and single substantially flat panel are coated with an intumescent or fire resistant material.