US2007110979A1PendingUtilityA1

Fiber-reinforced composite fire door

56
Assignee: JELD WEN INCPriority: Apr 21, 2004Filed: Nov 17, 2006Published: May 17, 2007
Est. expiryApr 21, 2024(expired)· nominal 20-yr term from priority
Inventors:Randy Jon ClarkRodney C. HarlinCraig R. TurnerGary Koepke
E04C 2/246Y10T428/249924B29L 2031/724B29C 70/30
56
PatentIndex Score
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Claims

Abstract

The present invention provides fiber-reinforced composites, and components for buildings, such as door skins, that include fiber-reinforced composites. Also provided are methods and systems for manufacturing fiber-reinforced composites that may be used in building structures. In an embodiment, the present invention provides a fiber-reinforced composite comprising long fibers of fiberglass and polyurethane produced using long-fiber injection (LFI) technology.

Claims

exact text as granted — not AI-modified
1 . A door comprising: 
 a first door skin comprising a fiber-reinforced composite;    a second door skin disposed opposite the first door skin, the second door skin comprising the fiber-reinforced composite; and    a core disposed between the first and second door skins, wherein the fiber-reinforced composite comprises a fiber and a polymer resin.    
     
     
         2 . The door of  claim 1 , wherein the door exhibits fire-resistance under positive pressure for at least 20 minutes as measured by at least one of standards UL 10(c), UBC 7-2 (1997) Part 1, NFPA 252, and ASTM E2074-00.  
     
     
         3 . The door of  claim 1 , wherein the door exhibits fire-resistance under neutral pressure for at least 20 minutes as measured by at least one of standards CAN/ULC S104, UL 10(b), UBC 7-2 (1994), and NFPA 252.  
     
     
         4 . The door of  claim 1 , wherein the polymer resin comprises a thermosetting polymer.  
     
     
         5 . The door of  claim 4 , wherein the thermosetting polymer comprises polyurethane.  
     
     
         6 . The door of  claim 1 , wherein the fiber comprises fiberglass.  
     
     
         7 . The door of  claim 1 , wherein the fiber ranges in length from about 5 mm to about 100 mm.  
     
     
         8 . The door of  claim 1 , wherein the fiber comprises a plurality of sectioned fibers arranged in a non-structured orientation.  
     
     
         9 . The door of  claim 1 , wherein the fiber-reinforced composite comprises a non-fiber filler.  
     
     
         10 . The door of  claim 1 , wherein the fiber-reinforced composite comprises a coloring agent.  
     
     
         11 . The door of  claim 1 , wherein the fiber-reinforced composite comprises at least one of a release agent, a barrier coat, or an in-mold coating.  
     
     
         12 . The door of  claim 1  further comprising a frame coupled with the first and second door skins.  
     
     
         13 . The door of  claim 12 , wherein the frame comprises at least one of a solid wood, laminated veneer lumber, finger-jointed wood, plastic, or metal.  
     
     
         14 . The door of  claim 12 , wherein the frame comprises a composite material.  
     
     
         15 . The door of  claim 1 , wherein the core comprises a particleboard.  
     
     
         16 . The door of  claim 15 , wherein a density of the particleboard comprises less than about 40 pounds per cubic foot.  
     
     
         17 . The door of  claim 1 , wherein the core comprises a fiberboard.  
     
     
         18 . The door of  claim 16 , wherein a density of the fiberboard comprises less than about 40 pounds per cubic foot.  
     
     
         19 . The door of  claim 1 , wherein the core comprises a thermoplastic polymer.  
     
     
         20 . The door of  claim 19 , wherein a density of the thermoplastic polymer comprises about one pound per cubic foot.  
     
     
         21 . A method of making a door comprising: 
 forming a door skin comprising a fiber-reinforced composite;    coupling the door skin with a frame; and    disposing a core between the door skin and the frame, wherein the fiber-reinforced composite comprises a fiber and a polymer resin.    
     
     
         22 . The method of  claim 21 , wherein forming the door skin comprises: 
 preparing a mold comprising an internal volume in the shape of the door skin;    dispensing a mixture comprising a plurality of the fibers and the polymer resin onto a surface of the mold; and    allowing the resin to polymerize under conditions sufficient to produce the fiber-reinforced composite.    
     
     
         23 . The method of  claim 21 , wherein the door exhibits fire-resistance under positive pressure for at least 20 minutes as measured by at least one of standards UL 10(c), UBC 7-2 (1997) Part 1, NFPA 252, and ASTM E2074-00.  
     
     
         24 . The method of  claim 21 , wherein the door exhibits fire-resistance under neutral pressure for at least 20 minutes as measured by at least one of standards CAN/ULC S104, UL 10(b), UBC 7-2 (1994), and NFPA 252.  
     
     
         25 . The method of  claim 21 , wherein the polymer resin comprises a thermosetting polymer.  
     
     
         26 . The method of  claim 25 , wherein the thermosetting polymer comprises polyurethane.  
     
     
         27 . The method of  claim 21 , wherein the fiber comprises fiberglass.  
     
     
         28 . The method of  claim 21 , wherein the fiber ranges in length from about 5 mm to about 100 mm.  
     
     
         29 . The method of  claim 22 , wherein the plurality of fibers comprises a plurality of chopped fibers arranged in a substantially random orientation.  
     
     
         30 . The method of  claim 22 , further comprising applying a surface-active agent to at least a portion of the mixture.  
     
     
         31 . The method of  claim 30 , wherein the surface-active agent comprises at least one of a release agent or a barrier coating.  
     
     
         32 . The method of  claim 22 , further comprising applying a surface-active agent to the surface of the mold.  
     
     
         33 . The method of  claim 32 , wherein the surface-active agent comprises at least one of a release agent, an in-mold coating, or a barrier coating.  
     
     
         34 . The method of  claim 21 , wherein the fiber-reinforced composite comprises a non-fiber filler.  
     
     
         35 . The method of  claim 21 , wherein the fiber-reinforced composite comprises a coloring agent.  
     
     
         36 . The method of  claim 21 , wherein the frame comprises at least one of a solid wood, laminated veneer lumber, finger-jointed wood, plastic, or metal.  
     
     
         37 . The method of  claim 21 , wherein the frame comprises a composite material.  
     
     
         38 . The method of  claim 21 , wherein the core comprises a particleboard.  
     
     
         39 . The method of  claim 38 , wherein a density of the particleboard comprises less than about 40 pounds per cubic foot.  
     
     
         40 . The method of  claim 21 , wherein the core comprises a fiberboard.  
     
     
         41 . The method of  claim 40 , wherein a density of the fiberboard comprises less than about 40 pounds per cubic foot.  
     
     
         42 . The method of  claim 21 , wherein the core comprises a thermoplastic polymer.  
     
     
         43 . The method of  claim 42 , wherein a density of the thermoplastic polymer comprises at least one pound per cubic foot.  
     
     
         44 . The method of  claim 22  further comprising bringing the surface of the mold in contact with the fibers and the resin.  
     
     
         45 . The method of  claim 21  further comprising adhering together the door skin and the core.  
     
     
         46 . The method of  claim 21  further comprising forming a simulated wood grain pattern on a surface of the door skin.

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