US 10,876,352 B2Granted

Fire rated door

AssigneeThe Intellectual Gorilla GmbH

InventorsEvan R. Daniels, Jonathan Newton

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Abstract

A fire rated door includes a core, a first decorative panel and a second decorative panel. The core includes: (a) a gypsum-based fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the gypsum-based fire resistant center panel is made of a first gypsum-based fire resistant material, and (b) an extruded gypsum-based fire resistant border attached to the first side, the second side, the first end and the second end of the gypsum-based fire resistant center panel, wherein the extruded gypsum-based fire resistant border is made of a second gypsum-based fire resistant material having a higher density than the first gypsum-based fire resistant material. The first decorative panel is attached to the top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border. The second decorative panel is attached to the bottom of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border.

Claims13

Dependent claims

A method of manufacturing a fire rated door comprising the steps of:

providing a gypsum-based fire resistant core comprising the steps of:
extruding a second gypsum-based fire resistant material to form a first gypsum-based fire resistant stile, a second gypsum-based fire resistant stile, a first gypsum-based fire resistant rail and a second gypsum-based fire resistant rail,
forming an extruded gypsum-based fire resistant border having a central void by attaching the first gypsum-based fire resistant rail to the first gypsum-based fire resistant stile, attaching a second gypsum-based fire resistant rail to the first gypsum-based fire resistant stile and attaching a second stile to the first gypsum-based fire resistant rail and the second gypsum-based fire resistant rail,
forming a gypsum-based fire resistant center panel by filling the void within the extruded gypsum-based fire resistant border with a first gypsum-based fire resistant material that has a lower density than the second gypsum-based fire resistant material, and wherein the first gypsum-based fire resistant material and the second gypsum-based fire resistant material are composed of water, gypsum, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents,
baking the extruded gypsum-based fire resistant border and first gypsum-based fire resistant material;
attaching a first decorative panel to a top of the core;
and
attaching a second decorative panel to a bottom of the core.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/114,594Filed 28 Aug 2018 · division
Priority: 29 Jun 2012
Published: US 2019/0032395 A131 Jan 2019
Granted: 29 Dec 2020
Term ends: Not estimatedThe source records don’t support an estimate.

Classification28 codes

E06B 5/161
Fireproof doors or similar closures; Adaptations of fixed constructions therefor: profile members therefor
B29C 39/10
For making articles of definite length, i.e. discrete articles: incorporating preformed parts or layers, e.g. casting around inserts or for…
B29C 48/001
Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor: combinations…
B29C 48/07
Characterised by the shape of the extruded material at extrusion: flat, e.g. panels

Family

Application13/538,828Parent of this division · filed 29 Jun 2012
Application14/997,812Parent of this division · filed 18 Jan 2016
US 9,243,444 B2Parent of this division · filed 26 Jan 2016
US 2019/0032395 A1Pre-grant publication · published 31 Jan 2019
US 10,077,597 B2Parent of this division
US 2014/0000194 A1Published application
US 2016/0130861 A1Published application
US 10,876,352 B2This patent

From the US filing history. Foreign family members aren’t listed.