US 9,243,444 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 fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material, and (b) an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material. The first decorative panel is attached to the top of the fire resistant center panel and the extruded fire resistant border. The second decorative panel is attached to the bottom of the fire resistant center panel and the extruded fire resistant border.

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

providing a gypsum-based fire resistant core comprising the steps of:
providing 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,
extruding a second gypsum-based fire resistant material to form a first gypsum-based fire resistant stile, a gypsum-based fire resistant second stile, a first gypsum-based fire resistant rail and a second gypsum-based fire resistant rail of an extruded fire resistant border, wherein the second gypsum-based fire resistant material has a higher density than the first gypsum-based fire resistant material, and 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,
attaching the first gypsum-based fire resistant stile of the extruded fire resistant border to the first side of the gypsum-based fire resistant center panel;
attaching the second gypsum-based fire resistant stile of the extruded fire resistant border to the second side of the gypsum-based fire resistant center panel,
attaching the first gypsum-based fire resistant rail of the extruded fire resistant border to the first end of the gypsum-based fire resistant center panel and the first gypsum-based fire resistant stile and the second gypsum-based fire resistant stile of the extruded fire resistant border, and
attaching the second gypsum-based fire resistant rail of the extruded fire resistant border to the second end of the gypsum-based fire resistant center panel and the first gypsum-based fire resistant stile and the second gypsum-based fire resistant stile of the extruded fire resistant border;
attaching a first decorative panel to a top of the gypsum-based fire resistant core;
and
attaching a second decorative panel to a bottom of the gypsum-based fire resistant core.

7 more elements

Facts

Application

13/538,828Filed 29 Jun 2012

Published

US 2014/0000194 A12 Jan 2014

Granted

26 Jan 2016

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

Abstract

Claims16