US2004003559A1PendingUtilityA1

Doors and methods of producing same

43
Priority: Apr 24, 2002Filed: Apr 29, 2003Published: Jan 8, 2004
Est. expiryApr 24, 2022(expired)· nominal 20-yr term from priority
Inventors:Ronald C. MinkeG. Daniel TempletonDavid R. ReddingSteven KeplerJohn E. Nemazi
B28B 1/50E06B 2003/703B28B 7/243E06B 5/16B28B 1/14B28B 19/00E06B 5/10B28B 7/42E06B 3/825E06B 2003/7063E06B 2003/7028E06B 2003/7067
43
PatentIndex Score
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Cited by
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References
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Claims

Abstract

One aspect of the present invention is directed to a door, and more specifically, to a door that includes a web and a rigid foamed core. In one embodiment, a door is disclosed which comprises a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity, a web disposed within the interior door cavity, and a rigid foamed cementitious core disposed within the interior door cavity and cooperating with the web.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A door comprising: 
 a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity;    a mat within the interior door cavity; and    a rigid foamed cementitious core within the interior door cavity.    
     
     
         2 . The door of  claim 1  wherein the mat includes openings.  
     
     
         3 . The door of  claim 2  wherein the mat is comprised of a web.  
     
     
         4 . The door of  claim 1  wherein the mat is comprised of a substantially rectangular plastic bladder filled with gas.  
     
     
         5 . The door of  claim 1  wherein the mat is comprised of a ballastic resistant material.  
     
     
         6 . The door of  claim 1  wherein the door shell is comprised of a blow-molding material.  
     
     
         7 . The door of  claim 6  wherein the blow-molding material is comprised of a pre-pigmented plastic.  
     
     
         8 . The door of  claim 6  wherein the blow-molding material is comprised of a thermoformed material.  
     
     
         9 . The door of  claim 8  wherein the thermoformed material is comprised of a twin-sheet thermoformed material.  
     
     
         10 . The door of  claim 1  further comprising an adhesive layer partially coating the internal surface of at least one door skin for at least partially adhering the rigid foamed cementitious core to the at least one door skin.  
     
     
         11 . The door of  claim 10  wherein the adhesive is selected from the group consisting of latex acrylic, hot melt urethane, epoxy, pressure sensitive adhesives, and radiation cured adhesives.  
     
     
         12 . The door of  claim 1  wherein the rigid foamed cementitious core cooperates with the mat.  
     
     
         13 . The door of  claim 1  wherein the rigid foamed cementitious core is comprised of a foamed cement core.  
     
     
         14 . The door of  claim 1  wherein the door skins are comprised of fiberglass.  
     
     
         15 . The door of  claim 1  wherein the door skins are comprised of a thermoplastic material.  
     
     
         16 . The door of  claim 3  wherein the rigid foamed cementitious core is disposed between the first and second door skins and on at least one side of the web.  
     
     
         17 . The door of  claim 3  wherein the rigid foamed cementitious core is disposed between the first and second door skins and on both sides of the web.  
     
     
         18 . The door of  claim 3  wherein the web is offset towards one of the door skins.  
     
     
         19 . The door of  claim 3  wherein the web is substantially centered in the interior door cavity.  
     
     
         20 . The door of  claim 3  wherein the web is closer to one of the door skins than to the other door skin.  
     
     
         21 . The door of  claim 3  wherein the web is comprised of a metal screen.  
     
     
         22 . The door of  claim 3  wherein the web is comprised of a polymer woven sheet.  
     
     
         23 . The door of  claim 1  wherein the rigid foamed cementitious core prevents the passage of fire for at least about 20 minutes using test method ASTM E 2074-00 or at least about 30 minutes using test method BSI 476/22.  
     
     
         24 . The door of  claim 23  wherein the rigid foamed cementitious core prevents the passage of fire for at least about 45 minutes using test method ASTM E2074-00 or at least about 60 minutes using test method BSI 476/22.  
     
     
         25 . The door of  claim 1  wherein the foamed cementitious core provides a sound transmission coefficient rating of at least about 27 using test method ASTM E-413.  
     
     
         26 . The door of  claim 1  wherein the foamed cementitious core has a compressive strength of at least about 210 kPa.  
     
     
         27 . The door of  claim 3  wherein at least two webs are disposed within the interior door cavity.  
     
     
         28 . The door of  claim 3  wherein the web is comprised of an expanded metal mesh.  
     
     
         29 . The door of  claim 28  wherein the door shell includes a door frame having first and second rails and first and second stiles.  
     
     
         30 . The door of  claim 29  wherein the expanded metal mesh includes apertures having a first dimension longer than a second dimension and the first dimension being substantially parallel to the first and second stiles.  
     
     
         31 . A door comprising: 
 a door frame and at least one door skin being connected and helping to define an interior door cavity;    a mat within the interior door cavity; and    a rigid foamed cementitious core within the interior door cavity.    
     
     
         32 . A method of constructing a door comprising: 
 providing a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity;    disposing a mat within the interior door cavity; and    disposing a rigid foamed cementitious core within the interior door cavity, the rigid foamed cementitious core cooperating with the web.    
     
     
         33 . The method of  claim 32  wherein the mat includes openings.  
     
     
         34 . The method of  claim 33  wherein the mat is comprised of a web.  
     
     
         35 . The method of  claim 34  wherein the web is disposed within the interior door cavity prior to disposing the rigid foamed cementitious core within the interior door cavity.  
     
     
         36 . The method of  claim 34  wherein the web is disposed offset towards one of the door skins.  
     
     
         37 . The method of  claim 34  wherein the web is disposed substantially centered in the interior door cavity.  
     
     
         38 . The method of  claim 34  further comprising securing the web to at least one of the door skins.  
     
     
         39 . The method of  claim 34  further comprising securing the web to the marginal edges of the door shell.  
     
     
         40 . The method of  claim 34  further comprising forming a shelf into the marginal edges of the door shell.  
     
     
         41 . The method of  claim 40  wherein the forming step is comprised of removing a portion of the marginal edges such that a first and second shelf surface is formed into the marginal edges.  
     
     
         42 . The method of  claim 41  wherein the first shelf surface is substantially parallel to the first and second doors skins and the second shelf surface is substantially perpendicular to the first and second door skins.  
     
     
         43 . The method of  claim 42  further comprising securing at least a portion of the web to at least a portion of the first shelf surface.  
     
     
         44 . The method of  claim 43  wherein the second shelf surface is offset towards one of the door skins.  
     
     
         45 . The method of  claim 44  wherein the second shelf surface is substantially centered between the first and second door skins.  
     
     
         46 . A door comprising: 
 a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity;    a polymeric shell disposed on the interior surface of at least one of the door skins; and    a rigid foam core disposed within the interior door cavity.    
     
     
         47 . The door of  claim 46  wherein the polymeric shell is the cured product of a curable mixture.  
     
     
         48 . The door of  claim 47  wherein the curable mixture includes a curable resin and a co-curable monomer.  
     
     
         49 . The door of  claim 48  wherein the curable mixture further includes a filler material.  
     
     
         50 . The door of  claim 49  wherein the curable mixture further includes a fibrous reinforcement material.  
     
     
         51 . The door of  claim 46  wherein the rigid foam core is comprised of a rigid foamed cementitious core.  
     
     
         52 . The door of  claim 51  wherein the rigid foamed cementitious core is comprised of a foamed cement core.  
     
     
         53 . The door of  claim 46  wherein the rigid foam core is comprised of a rigid foamed polyurethane core.  
     
     
         54 . A door comprising: 
 a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity;    a mat disposed within the interior door cavity and offset towards one of the door skins; and    a rigid foamed polyurethane core disposed within the interior door cavity and cooperating with the mat.    
     
     
         55 . The door of  claim 54  wherein the mat includes openings.  
     
     
         56 . The door of  claim 55  wherein the mat is comprised of a web.  
     
     
         57 . The door of  claim 56  wherein the web is comprised of expanded metal mesh.  
     
     
         58 . The door of  claim 57  wherein the door shell includes a door frame having first and second rails and first and second stiles.  
     
     
         59 . The door of  claim 58  wherein the expanded metal mesh includes apertures having a first dimension longer than a second dimension and the first dimension being substantially parallel to the first and second stiles.  
     
     
         60 . The door of  claim 56  wherein the rigid foamed polyurethane core is comprised of the cured product of a polyurethane foam.  
     
     
         61 . The door of  claim 60  wherein the polyurethane foam has a density of at least about 2.0 lb/ft 3 .  
     
     
         62 . A door comprising: 
 a door shell having a generally planar construction with marginal edges and interior and exterior door skins helping to define an interior door cavity;    a web means for preventing access to the interior door skin from the exterior door skin, the web means being within the interior door cavity; and    a rigid foamed cementitious core extending between and connecting at least portions of the interior and exterior door skins.    
     
     
         63 . The door of  claim 62  wherein the rigid foamed cementitious core extends between and connects substantial portions of the skins.  
     
     
         64 . The door of  claim 62  wherein the rigid foamed cementitious core is comprised of a rigid foamed cement core.  
     
     
         65 . The door of  claim 62  wherein the rigid foamed cementitious core prevents the passage of fire for at least about 20 minutes using test method ASTM E 2074-00 or at least about 30 minutes using test method BSI 476/22.  
     
     
         66 . The door of  claim 65  wherein the rigid foamed cementitious core prevents the passage of fire fore at least 45 minutes using test method ASTM E2074-00 or at least about 60 minutes using test method BSI 476/22.  
     
     
         67 . The door of  claim 62  wherein the foamed cementitious core provides a sound transmission coefficient rating of at least about 27 using test method ASTM E-413.  
     
     
         68 . The door of  claim 62  wherein the foamed cementitious core has a compressive strength of at least about 210 kPa.

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