Method for producing fire rated door by inserting intumescent material in a perimeter channel of a first and second door panel
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E06B-005/16
E06B-003/70
출원번호
US-0899742
(2010-10-07)
등록번호
US-8209866
(2012-07-03)
발명자
/ 주소
Daniels, Evan R.
출원인 / 주소
Polymer-Wood Technologies, Inc.
대리인 / 주소
Chalker, Daniel J.
인용정보
피인용 횟수 :
15인용 특허 :
14
초록▼
The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resistant material,
The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resistant material, lead sheeting, steel or Kevlar) can be added between the door panels for various purposes. Splines, stiles or sticks are inserted in longitudinal channels in the door panels to provide assistance in aligning the door panels and greater hardware holding strength. An intumescent banding material concealed by a banding material around the perimeter of the door seals the door within its frame during a fire. The door design and the automated manufacturing process provide greater design choice, reduced cost and faster fabrication.
대표청구항▼
1. A method for manufacturing a fire rated door comprising the steps of: providing a first door-sized panel having two longitudinal interior channels cut into a back side of the first door-sized panel, and a second door-sized panel having two longitudinal interior channels cut into a back side of a
1. A method for manufacturing a fire rated door comprising the steps of: providing a first door-sized panel having two longitudinal interior channels cut into a back side of the first door-sized panel, and a second door-sized panel having two longitudinal interior channels cut into a back side of a second door-sized panel;assembling a door slab by (a) inserting a spline in each longitudinal interior channel of the first door-sized panel, (b) attaching the back side of the second door-sized panel directly to (i) the splines inserted in the first door-sized panel such that the splines are also inserted into the longitudinal interior channels of the second door-sized panel and (ii) the back of the first door-sized panel using an adhesive, and (c) applying pressure to the door slab to bond the splines and the door-sized panels together;cutting a perimeter channel in each side of the door slab;inserting (a) an intumescent banding material in each perimeter channel, and (b) an exterior banding in each perimeter channel to conceal the intumescent banding material within the perimeter channel; andwherein the fire rating for the door is achieved without a mineral core disposed between the first door-sized panel and the second door sized panel by (a) the intumescent banding material and (b) one or more of the following: (i) the adhesive is fire resistant, (ii) the first door-sized panel and the second door-sized panel contain an intumescent or fire resistant material, or (iii) the first door-sized panel and the second door-sized panel are coated with the intumescent or fire resistant material. 2. The method as recited in claim 1, wherein the step of providing the first door-sized panel and the second door-sized panel comprises the steps of: cutting two longitudinal interior channels into a back side of a first door-sized panel; andcutting two longitudinal interior channels into a back side of a second door-sized panel. 3. The method as recited in claim 1, wherein the first door-sized panel and the second door-sized panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard or a combination thereof. 4. The method as recited in claim 1, wherein the perimeter channel along the longitudinal sides of the first door-sized panel and the second door-sized panel extend to the spline. 5. The method as recited in claim 1, wherein the splines contain an intumescent or fire resistant material, or are coated with an intumescent or fire resistant material. 6. The method as recited in claim 1, further comprising the step of embedding a data device containing production data within the door slab. 7. The method as recited in claim 6, wherein the production data comprises a date that the door was manufactured, a time that the door was manufactured, an order number, a purchase number, a product identifier, a purchaser identifier, a shift identifier, a personnel identifier, a machine line identifier, one or more specifications for the door, a list of hardware for the door, a size of the door, a style of the door, a routing design identifier, a parts list, an options identifier, a special features identifier, an assembly program or a combination thereof. 8. The method as recited in claim 1, further comprising the steps of: cutting a large interior channel into the back of the first door-sized panel and/or the back of the second door-sized panel between the two longitudinal interior channels; andinserting one or more protective layers into the large interior channel. 9. The method as recited in claim 8, wherein the one or more protective layers comprise an additional 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. 10. The method as recited in claim 8, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof. 11. The method as recited in claim 8, wherein the one or more protective layers contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 12. The method as recited in claim 1, further comprising the step of applying one or more primer coats to the door slab. 13. The method as recited in claim 12, wherein the one or more primer coats include an intumescent material. 14. The method as recited in claim 12, wherein the one or more primer coats are applied with an electrostatic powder coating process. 15. The method as recited in claim 1, further comprising the step of injecting a chemical into one or more screw pilot holes to increase screw holding capacity or pull strength. 16. The method as recited in claim 1, further comprising the step of routing a specified design into a front side of the first door-sized panel and/or a front side of the second door-sized panel. 17. The method as recited in claim 1, further comprising the step of machining the door slab to receive a set of hinges and lockset hardware. 18. A method for manufacturing a fire rated door comprising the steps of: providing a first door-sized panel having two longitudinal interior channels cut into a back side of the first door-sized panel, and a second door-sized panel having two longitudinal interior channels cut into a back side of a second door-sized panel, and wherein a large interior channel is cut into the back of the first door-sized panel and/or the back of the second door-sized panel between the two longitudinal interior channels;assembling a door slab by (a) inserting a spline in each longitudinal interior channel of the first door-sized panel, (b) inserting one or more protective layers into the large interior channel, (c) attaching the back side of the second door-sized panel directly to (i) the splines inserted in the first door-sized panel such that the splines are also inserted into the longitudinal interior channels of the second door-sized panel and (ii) the back of the first door-sized panel using an adhesive, and (d) applying pressure to the door slab to bond the splines, protective layers and the door-sized panels together;cutting a perimeter channel in each side of the door slab;inserting (a) an intumescent banding material in each perimeter channel, and (b) an exterior banding in each perimeter channel to conceal the intumescent banding material within the perimeter channel; andwherein the fire rating for the door is achieved without a mineral core disposed between the first door-sized panel and the second door-sized panel by (a) the intumescent banding material and (b) one or more of the following: (i) the adhesive is fire resistant, (ii) the first door-sized panel and the second door-sized panel contain an intumescent or fire resistant material, or (iii) the first door-sized panel and the second door-sized panel are coated with the intumescent or fire resistant material. 19. The method as recited in claim 18, wherein the step of providing the first door-sized panel and the second door-sized panel comprises the steps of: cutting two longitudinal interior channels into the back side of the first door-sized panel;cutting two longitudinal interior channels into the back side of the second door-sized panel; andcutting a large interior channel into the back of the first door-sized panel and/or the back of the second door-sized panel between the two longitudinal interior channels. 20. The method as recited in claim 18, wherein the first door-sized panel and the second door-sized panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard or a combination thereof. 21. The method as recited in claim 18, wherein the perimeter channel along the longitudinal sides of the first door-sized panel and the second door-sized panel extend to the spline. 22. The method as recited in claim 18, wherein the splines contain an intumescent or fire resistant material, or are coated with an intumescent or fire resistant material. 23. The method as recited in claim 18, further comprising the step of embedding a data device containing production data within the door slab. 24. The method as recited in claim 23, wherein the production data comprises a date that the door was manufactured, a time that the door was manufactured, an order number, a purchase number, a product identifier, a purchaser identifier, a shift identifier, a personnel identifier, a machine line identifier, one or more specifications for the door, a list of hardware for the door, a size of the door, a style of the door, a routing design identifier, a parts list, an options identifier, a special features identifier, an assembly program or a combination thereof. 25. The method as recited in claim 18, wherein the one or more protective layers comprise an additional 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. 26. The method as recited in claim 18, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof. 27. The method as recited in claim 18, wherein the one or more protective layers contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 28. The method as recited in claim 18, further comprising the step of applying one or more primer coats to the door slab. 29. The method as recited in claim 28, wherein the one or more primer coats include an intumescent material. 30. The method as recited in claim 28, wherein the one or more primer coats are applied with an electrostatic powder coating process. 31. The method as recited in claim 18, further comprising the step of injecting a chemical into one or more screw pilot holes to increase screw holding capacity or pull strength. 32. The method as recited in claim 18, further comprising the step of routing a specified design into a front side of the first door-sized panel and/or a front side of the second door-sized panel. 33. The method as recited in claim 18, further comprising the step of machining the door slab to receive a set of hinges and lockset hardware. 34. A method for manufacturing a fire rated door comprising the steps of: cutting two longitudinal interior channels into a back side of a first door-sized panel;cutting two longitudinal interior channels into a back side of a second door-sized panel;wherein the first door-sized panel and the second door-sized panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard or a combination thereof;cutting a large interior channel into the back of the first door-sized panel and/or the back of the second door-sized panel between the two longitudinal interior channels;assembling a door slab by (a) inserting a spline in each longitudinal interior channel of the first door-sized panel, (b) inserting one or more protective layers into the large interior channel, (c) attaching the back side of the second door-sized panel directly to (i) the splines inserted in the first door-sized panel such that the splines are also inserted into the longitudinal interior channels of the second door-sized panel and (ii) the back of the first door-sized panel using an adhesive, and (d) applying pressure to the door slab to bond the splines, protective layers and the door-sized panels together;cutting a perimeter channel in each side of the door slab;inserting (a) an intumescent banding material in each perimeter channel, and (b) an exterior banding in each perimeter channel to conceal the intumescent banding material within the perimeter channel;routing a specified design into a front side of the first door-sized panel and/or a front side of the second door-sized panel;machining the door slab to receive a set of hinges and lockset hardware;applying one or more primer coats to the door slab; andwherein the fire rating for the door is achieved without a mineral core disposed between the first door-sized panel and the second door-sized panel by (a) the intumescent banding material and (b) one or more of the following: (i) the adhesive is fire resistant, (ii) the first door-sized panel and the second door-sized panel contain an intumescent or fire resistant material, or (iii) the first door-sized panel and the second door-sized panel are coated with the intumescent or fire resistant material. 35. The method as recited in claim 34, wherein the perimeter channel along the longitudinal sides of the first door-sized panel and the second door-sized panel extend to the spline. 36. The method as recited in claim 34, wherein the splines contain an intumescent or fire resistant material, or are coated with an intumescent or fire resistant material. 37. The method as recited in claim 34, further comprising the step of embedding a data device containing production data within the door slab. 38. The method as recited in claim 37, wherein the production data comprises a date that the door was manufactured, a time that the door was manufactured, an order number, a purchase number, a product identifier, a purchaser identifier, a shift identifier, a personnel identifier, a machine line identifier, one or more specifications for the door, a list of hardware for the door, a size of the door, a style of the door, a routing design identifier, a parts list, an options identifier, a special features identifier, an assembly program or a combination thereof. 39. The method as recited in claim 34, wherein the one or more protective layers comprise an additional 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. 40. The method as recited in claim 34, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof. 41. The method as recited in claim 34, wherein the one or more protective layers contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 42. The method as recited in claim 34, wherein the one or more primer coats include an intumescent material. 43. The method as recited in claim 34, wherein the one or more primer coats are applied with an electrostatic powder coating process. 44. The method as recited in claim 34, further comprising the step of injecting a chemical into one or more screw pilot holes to increase screw holding capacity or pull strength.
Andre Fortin CA; Leo F. Juhl DK, Fire resistant door edge construction comprising a stile with groove, high density strip in the groove, an intumescent strip seal, covered by an edge lipping.
Clark,Randy Jon; Koepke,Gary Lee; Lewallen,Keith Lynn; Olson,Brent David; Transue,William Robert, Multi-layered fire door and method for making the same.
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