Fire door core assembly
AssigneeDorset Firedoor Systems, Inc.
InventorAndre Fortin
Life of this patent
Estimating the term…
Abstract
A fire resistant wood door is formed from an opposing pair of rails interconnected by a upper and lower stiles forming an outer frame. A wood laminate core is provided within the outer frame and covered by outer sheathing. The wood laminate core is formed from first and second panels and a heat barrier layer. Each of the first and second panels is formed from an organic material and provided with a plurality of grooves on one surface. The heat barrier layer is in the form of a casting applied to the grooved surface of at least one, and preferably both, of the first and second panels. The panels are then joined together with the heat barrier layer sandwiched therebetween. When joined with the outer frame and sheathing, a wood door is formed having a fire rating of at least 45 minutes.
Claims30
A fire resistant wood door comprising:
- an outer peripheral frame;
- and
- a two panel wood laminate core including:
- a first panel formed from an organic material including first and second opposing planar surfaces and a plurality of grooves, said grooves being formed in the first planar surface of the first panel;
- a second panel formed from an organic material including first and second opposing planar surfaces and a plurality of grooves, said grooves being formed in the first planar surface of the second panel;
- and
- a heat barrier layer arranged between the first planar surface of the first panel and the first planar surface of the second panel, said heat barrier layer being formed from a flame resistant casting extending into the plurality of grooves of each of the first and second panels, wherein the first and second panels are pressed together with the heat barrier layer sandwiched therebetween to form the two panel wood laminate core, said two panel wood laminate core being arranged within the outer peripheral frame to form a door having a fire rating of at least 45 minutes.
A two panel wood laminate core for a fire resistant door having a fire rating of at least 45 minutes comprising:
- a first panel formed from an organic material including first and second opposing planar surfaces and a plurality of grooves, said grooves being formed in the first planar surface of the first panel;
- a second panel formed from an organic material including first and second opposing planar surfaces and a plurality of grooves, said grooves being formed in the first planar surface of the second panel;
- and
- a heat barrier layer arranged between the first planar surface of the first panel and the first planar surface of the second panel, said heat barrier layer being formed from a flame resistant casting extending into the plurality of grooves of each of the first and second panels, wherein the first and second panels are pressed together with the heat barrier layer sandwiched therebetween to form the two panel wood laminate core for use in a door having a fire rating of at least 45 minutes.
A method of forming a two panel fire resistant wood door core comprising:
- creating grooves on one side of a first panel formed from an organic material;
- creating grooves on one side of a second panel formed from an organic material;
- coating the one side of at least one of the first and second panels with a casting material to form a heat barrier layer;
- and
- joining the first and second panels with the heat barrier layer being sandwiched between the first and second panels and extending into the grooves to form a wood laminate core for use in making a dual panel door having a fire rating of at least 45 minutes.
Dependencies are inferred from the claim text.