Method of and system for forming a fire door core
AssigneePremdor International, Inc.
InventorsHartley Moyes, Michael Windsor Symons
Life of this patent
Estimating the term…
Abstract
A method and system of forming a fire door core. Hydraulic binder and resin are supplied from raw material bins and mixed to provide a submixture. Exfoliated vermiculite is then mixed with the submixture to provide a mixture that is deposited into a plurality of compression molds. Each of the filled molds are pressed in a press at a predetermined temperature at a predetermined pressure for a predetermined period of time sufficient to harden the mixture into a hardened slab. The hardened slabs are then removed from the molds, impregnated with water or steam in a water impregnation assembly and dried in a drying assembly.
Claims32
A method of forming fire door components of resin bonded vermiculate and hydraulic binder, comprising the steps of:
- a) depositing into a mold a mixture of exfoliated vermiculite, a resin and a hydraulic binder, the mold being maintained at a temperature less than the reaction temperature of the resin;
- b) transferring the mold and thereby the mixture to a heated press;
- c) applying to the mixture through the press a predetermined pressure at a predetermined temperature for a predetermined period sufficient to harden the mixture into a fire door core having a density from about 350 kg/m3 to about 600 kg/m3;
- and
- d) removing the hardened fire door core from the mold.
A method of forming a fire door core, comprising the steps of:
- a) depositing into a mold a mixture of exfoliated vermiculite, a resin and a hydraulic binder;
- b) controlling a temperature of the mold such that the mold is maintained at a temperature less than the reaction temperature of the resin;
- c) transferring the mold and thereby the mixture to a heated press;
- d) applying to the mixture through the press a predetermined pressure at a predetermined temperature for a predetermined period sufficient to harden the mixture into a fire retardant fire door core having basic properties meeting industry-wide fire endurance tests;
- and
- e) removing the hardened fire retardant fire door core from the mold;
- wherein the hardened fire retardant fire door core has good integrity and dimensional stability when exposed to fire temperatures.
A fire retardant fire door core forming system, comprising:
- a) a plurality of raw material sources for storing raw materials including exfoliated vermiculite, resin, and hydraulic binder;
- b) a mixing system, said mixing system in communication with said raw material sources, said mixing system comprising a first mixing assembly for combining said resin and said hydraulic binder to create a submixture and a second mixing assembly in communication with said first mixing assembly for combining said submixture with said exfoliated vermiculite to create a final mixture;
- c) a plurality of molds, each mold in operative communication with said second mixing assembly for receiving a predetermined supply of said final mixture of said raw materials from said second mixing assembly thereby providing a plurality of filled molds;
- d) a vibratory assembly for receiving each of said filled molds and for causing said final mixture of said raw materials in said filled molds to achieve a substantially uniform density in each of the associated filled and vibrated molds;
- and
- e) a heated press in operative association with said vibratory assembly for receiving the filled and vibrated molds and for applying sufficient heat and pressure for a sufficient period to cause said final mixture of said raw materials in each of said filled and vibrated molds to form fire retardant fire door cores having a hardened state.
Dependencies are inferred from the claim text.