U.S. patent application number 09/931828 was filed with the patent office on 2003-02-20 for fire door assembly.
Invention is credited to Yulkowski, Leon.
Application Number | 20030033786 09/931828 |
Document ID | / |
Family ID | 25461412 |
Filed Date | 2003-02-20 |
United States Patent
Application |
20030033786 |
Kind Code |
A1 |
Yulkowski, Leon |
February 20, 2003 |
Fire door assembly
Abstract
A door assembly includes a plurality of spacers. The spacers
have a first side and a second side. A first sheet of
fire-resistant insulating material is coupled to the first side. A
second sheet of fire-resistant insulating material is coupled to
the second side. A first outer skin is coupled to the first sheet
opposite said plurality of spacers. A second outer skin is coupled
to the second sheet opposite the plurality of spacers.
Inventors: |
Yulkowski, Leon; (Bloomfield
Hills, MI) |
Correspondence
Address: |
ARTZ & ARTZ, P.C.
Suite 250
28333 Telegraph Road
Southfield
MI
48034
US
|
Family ID: |
25461412 |
Appl. No.: |
09/931828 |
Filed: |
August 17, 2001 |
Current U.S.
Class: |
52/784.15 ;
52/784.11; 52/784.14; 52/802.1; 52/802.11 |
Current CPC
Class: |
E06B 5/16 20130101 |
Class at
Publication: |
52/784.15 ;
52/784.11; 52/784.14; 52/802.1; 52/802.11 |
International
Class: |
E04C 002/54; E04C
002/38 |
Claims
What is claimed is:
1. A door assembly comprising: a spacer having a first side and a
second side; a first sheet of fire-resistant insulating material
coupled to said first side; a second sheet of fire-resistant
insulating material coupled to said second side; a first outer skin
coupled adjacent to said first sheet opposite said spacer; and a
second outer skin coupled adjacent to said second sheet opposite
spacer.
2. A door assembly as recited in claim 1 wherein said first
fire-resistant insulating material and said second fire-resistant
insulating material comprises a gypsum-based material.
3. A door assembly as recited in claim 1 wherein said gypsum based
material has a fibrous mat therearound.
4. A door assembly as recited in claim 1 wherein said spacer is
selected from the group of wood spacers, gypsum pads, concrete,
corrugated cardboard, and a honeycomb material.
5. A door assembly as recited in claim 1 wherein said spacer is
formed of a plurality of studs.
6. A door assembly as recited in claim 5 wherein said plurality of
studs are composed of steel.
7. A door assembly as recited in claim 1 wherein spacer, said first
outer skin and said second outer skin form a void therebetween.
8. A door assembly as recited in claim 7 wherein said void has fill
material therein.
9. A door assembly comprising: a first vertical edge; a second
vertical edge space apart from said first vertical edge; a top rail
coupled to said first vertical edge and said second vertical edge;
a bottom rail spaced apart from said top rail coupled to said first
vertical edge and said second vertical edge; a plurality of
spaced-apart spacers disposed between said first vertical edge,
said second vertical edge, said top rail and said bottom rail, said
plurality of spaced-apart spacers having a first side and a second
side; a first sheet of fire-resistant insulating material coupled
to said first side; a second sheet of fire-resistant insulating
material coupled to said second side; a first outer skin coupled to
said first sheet opposite said plurality of spacers; and a second
outer skin coupled to said second sheet opposite said plurality of
spacers.
10. A door assembly as recited in claim 9 wherein said first sheet
of fire-resistant insulating material is coupled to said first
vertical edge, said second vertical edge, said top rail and said
bottom rail.
11. A door assembly as recited in claim 9 wherein said first sheet
of fire-resistant insulating material is coupled to said first
vertical edge, said second vertical edge, said top rail and said
bottom rail.
12. A door assembly as recited in claim 9 wherein said first
fire-resistant insulating material and said second fire-resistant
insulating material comprises a gypsum-based material.
13. A door assembly as recited in claim 9 wherein said gypsum based
material has a fibrous mat therearound.
14. A door assembly s recited in claim 9 wherein said plurality of
spaced-apart spacers are selected from the group of wood spacers,
gypsum pads, concrete, corrugated cardboard, and a honeycomb
material.
15. A door assembly as recited in claim 9 wherein said plurality of
spaced-apart spacers are formed of studs.
16. A door assembly as recited in claim 15 wherein said plurality
of studs are composed of steel.
17. A door assembly as recited in claim 9 wherein said plurality of
spaced-apart spacers, said first outer skin and said second outer
skin form a void therebetween.
18. A door assembly as recited in claim 16 wherein said void has
fill material therein.
19. A door assembly as recited in claim 9 wherein said first sheet
of fire-resistant insulating material, said second sheet of
fire-resistant insulating material, and said plurality of
spaced-apart spacers comprise a core having a predetermined
thickness, said first vertical edge, said second vertical edge,
said top rail and said bottom rail having said predetermined
thickness.
20. A method of forming a door comprising: coupling a plurality of
spaced-apart spacers between a first sheet of fire-resistant
insulating material and a second sheet of fire-resistant insulating
material; coupling a first outer skin to the first sheet of
fire-resistant insulating material; and coupling a second outer
skin to the second sheet of fire-resistant insulating material.
21. A method as recited in claim 20 wherein coupling forms a void
between said plurality of spaced-apart studs, said first sheet of
fire-resistant insulating material and said second sheet of
fire-resistant insulating material.
22. A method as recited in claim 20 further comprising filling said
void with a fire-resistant insulating material.
23. A method as recited in claim 20 wherein coupling a plurality of
spaced-apart spacers comprises coupling a plurality of spaced-apart
studs between a first sheet of fire-resistant insulating material
and a second sheet of fire-resistant insulating material.
24. A door assembly comprising: a first vertical edge; a second
vertical edge space apart from said first vertical edge; a top rail
coupled to said first vertical edge and said second vertical edge;
a bottom rail spaced apart from said top rail coupled to said first
vertical edge and said second vertical edge; a plurality of
spaced-apart spacers disposed between said first vertical edge,
said second vertical edge, said top rail and said bottom rail, said
plurality of spaced-apart spacers having a first side and a second
side; a first sheet of fire-resistant insulating material coupled
to said first side; and a second sheet of fire-resistant insulating
material coupled to said second side.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to an entry door for
a building and, more specifically, to a fire-resistant building
door construction.
BACKGROUND OF THE INVENTION
[0002] Fire-resistant doors or fire doors as they are referred to
in the industry, are used in various locations throughout a
commercial building. Fire doors may also be used in residential
buildings in accordance with various local codes.
[0003] One type of fire door uses a thick sheet of fire-resistant
insulating material that completely fills the area between the
outer skins of the door. The fire-resistant insulating material is
a dense material that substantially increases the weight of the
door. Also, known types of fire-resistant insulating materials are
relatively expensive. One completely filled solid core door is
described in U.S. Pat. No. 4,695,494. Because this door uses the
fire-resistant insulating material through its thickness the cost
and weight are relatively high.
[0004] Another fire-resistant door is described in U.S. Pat. No.
4,811,538. This door comprises a single sheet of fire-resistant
insulating material that is support between the door skins. Spacers
are provided on either side of the fire-resistant insulating
material to support the door skins. Upon the testing of a similar
configuration, applicant concluded that such a door configuration
does not provide adequate fire protection during testing.
[0005] It would therefore be desirable to provide a fire-resistant
door that is less expensive to manufacture than current doors as
well as fire-resistant to predetermined codes.
[0006] It would therefore be desirable to provide a fire resistant
door assembly that reduces the cost of the installation of the
door.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved fire-resistant
door that includes a plurality of spacers. The spacers have a first
side and a second side. A first sheet of fire-resistant insulating
material coupled to the first side. A second sheet of
fire-resistant insulating material is coupled to the second side. A
first outer skin is coupled to the first sheet opposite said
plurality of spacers. A second outer skin is coupled to the second
sheet opposite the plurality of spacers.
[0008] A method for assembling a door comprises:
[0009] coupling a plurality of spaced-apart spacers between a first
sheet of fire-resistant insulating material and a second sheet of
fire-resistant insulating material;
[0010] coupling a first outer skin to the first sheet of
fire-resistant material; and
[0011] coupling a second outer skin to the second sheet of
fire-resistant insulating material.
[0012] One advantage of the invention is that by providing a void
between the layers of fire-resistant insulating material, the door
is lighter weight than previously known fire doors. Also, the doors
are less costly because the fire-resistant insulating material does
not extend through the thickness of the door.
[0013] Other advantages and features of the present invention will
become apparent when viewed in light of the detailed description of
the preferred embodiment when taken in conjunction with the
attached drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an elevational view of a door assembly according
to the present invention.
[0015] FIG. 2 is a cross-sectional view of a door assembly in a
closed position according to the present invention.
[0016] FIG. 3 is an exploded view of a door assembly according to
the present invention.
[0017] FIG. 4 is a partial cross-section of an alternative
embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] In the following figures, the same reference numerals will
be used to illustrate the same components in the various views. The
present invention is described and illustrated with respect to
flat-skinned commercial doors. However, various types of shapes and
style doors may be formed according to the present invention.
[0019] Referring now to FIGS. 1-3, a door 10 is illustrated having
a frame 12 around its perimeter. Frame 12 comprises a horizontal
header 14 and vertical jambs 16 that are used for mounting the door
within the building. Horizontal header 14 and vertical jambs 16 may
be formed of a variety of materials including wood, metal or a
composite material. Preferably, in commercial door environments,
horizontal header 14 and vertical jambs 16 are formed from metal.
As is best shown in FIG. 2, a fire stop 15 may be coupled to header
14.
[0020] Door 10 has around its periphery a hinge edge or stile 18, a
latch edge or stile 20 spaced apart from the hinge stile. Edge is
used in a broad sense herein and is meant to include both stiles
and other types of door constructions that do not have stiles. The
distance between hinge stile 18 and latch stile 20 inclusive
defines the width of the door. A top rail 22 extends between hinge
stile 18 and latch stile 20. A bottom rail 24 is spaced apart from
top rail 22 and extends between hinge stile 18 and latch stile 20.
The distance between top rail 22 and bottom rail 24 inclusive
defines the height of the door. Preferably, hinge stile 18, latch
stile 20, top rail 22, and bottom rail 24 are formed of steel.
Hinge stile 18 is used to mount door 10 rotatably within frame 12.
Latch stile 20 is used to mount a latch for holding a door in a
closed position. Of course, those skilled in the art will recognize
other materials may be used.
[0021] Outer skins 26A and 26B are mounted to hinge stile 18, latch
stile 20, top rail 22, and bottom rail 24. One suitable material
for outer skins is 18 gauge steel. If outer skins 26A and 26B,
hinge stile 18, latch stile 20, top rail 22, and bottom rail 24 are
formed of steel, MIG welding is a suitable method for fastening
outer skin to the stiles and rails. Of course, other methods using
fasteners or adhesives may be used.
[0022] Outer skins 26A, 26B, and stiles 18, 20 and rails 22, 24
have a fire-resistant core 28 therebetween. Core 28 is formed of a
plurality of spaced apart spacers 30 and a first sheet of
fire-resistant insulating material 32 and a second sheet of
fire-resistant insulating material 34 coupled to a respective first
side and second side of the spacers 30. The thickness T of core is
preferably the same thickness as hinge stile 18, latch stile 20,
top rail 22, and bottom rail 24. That is, spacers 30 are preferably
less than the thickness of hinge stile 18, latch stile 20, top rail
22, and bottom rail 24.
[0023] Spacers 30 may be formed of a number of materials including
wood spacers, gypsum pads, concrete, corrugated cardboard, a
honeycomb material, or as in the preferred embodiment, steel studs.
Various cross-sectionally shaped steel studs may be used including
rectangular, I-shaped, H-shaped, and irregular shapes. In one
constructed embodiment the steel studs were 20 gauge, 1-{fraction
(1/16)} inch by 1 inch.
[0024] The first sheet of fire-resistant insulating material 32 and
the second sheet of fire-resistant insulating material 34 are
preferably formed of a gypsum-based product. Of course, other
fire-resistant mineral based products may be used. One suitable
material for fire-resistant insulating material includes
Dens-Deck.RTM. roof board manufactured by Georgia-Pacific Gypsum
Corporation. In one constructed embodiment, for example,
one-quarter inch Dens-Deck.RTM. material was used for each sheet.
The Dens-Deck.RTM. material has a fibrous mat 35 (only a portion of
which is shown in FIG. 3) exterior with a conventional gypsum board
interior. The fibrous mat may, for example, comprise glass fibers
which strengthen the material for handling during the door
assembly. The gypsum interior may be formed from calcined gypsum
and water in a known manner. Of course, other suitable
fire-resistant insulating materials may also be used such as
fiberglass.
[0025] The first sheet of fire-resistant insulating material 32 and
the second sheet of fire-resistant insulating material 34 may be
coupled to spacers 30 in various manners including the use of
adhesives, fasteners or a combination thereof. Also, outer skins
26A and 26B may also be fastened to the first sheet of
fire-resistant insulating material 32 and the second sheet of
fire-resistant insulating material 34 through the use of adhesives.
It should be noted that the fire-resistant insulating material may
be finishable to provide a desirable aesthetically pleasing
appearance. Therefore, outer skins 26A and 26B may be eliminated in
some commercial embodiments.
[0026] A void 36 is preferably formed between spacers 30 and the
first sheet of fire-resistant insulating material 32 and the second
sheet of fire-resistant insulating material 34. Void 36 is
essentially an air space. By providing a void rather than
completely filling the door space with a relatively heavy
fire-resistant insulating material the door weight is reduced.
[0027] Referring now to FIG. 4, a fill material 38 may be used to
fill void 36. Fill material 38 is preferably also fire-resistant
insulating material and may comprise fiberglass insulation.
Fiberglass insulation has the advantage of not being as dense as a
gypsum-based material and therefore does not substantially increase
the weight of the door.
[0028] To assemble a door, the following process is preferably
used. The steps described here may be formed in various orders and
therefore is not meant to be limiting. In one constructed
embodiment the steel studs were positioned at a maximum of twelve
inches on center. Thus, for a large commercial door about four
spacers 30 may be used as illustrated in FIG. 1. The spacers 30 are
preferably positioned vertically between and parallel with hinge
stile 18 and latch stile 20. Those skilled in the art will
recognize that various orientations of spacers 30 may be used
depending on the type of spacer. The spacers 30 are also positioned
between the top rail 22 and bottom rail 24. The first sheet of
fire-resistant insulating material 32 and the second sheet of
fire-resistant insulating material 34 are coupled to the spacers 30
and preferably extend to hinge stile 18, latch stile 20, top rail
22, and bottom rail 24. Fasteners or adhesives or a combination
thereof may be used. If a thicker door is desired, the first sheet
of fire-resistant insulating material 32 and the second sheet of
fire-resistant insulating material 34 may extend over hinge stile
18, latch stile 20, top rail 22, and bottom rail 24.
[0029] The outer skins 26A and 26B are coupled to the first sheet
of fire-resistant insulating material 32 and the second sheet of
fire-resistant insulating material 34, respectively. Outer skins
26A and 26B may also be coupled to hinge stile 18, latch stile 20,
top rail 22, and bottom rail 24. Once outer skins 26A and 26B are
coupled thereto, the door may be installed into a frame prior to
shipping or may be installed in the frame once on a jobsite. Hinges
and other door hardware (not shown) may be coupled to hinge stile
18 and a door latch to latch stile 20.
[0030] While particular embodiments of the invention have been
shown and described, numerous variations and alternate embodiments
will occur to those skilled in the art. Accordingly, it is intended
that the invention be limited only in terms of the appended
claims.
* * * * *