Abstract:
A fireproof door assembly structure comprising: two molded door panels of compression molded thin skins overlaid with each other to form door with a hollow core; a rectangular frame sealing on said door panels operable to said frame of the opposing panel when said panels are overlaid with one another; a reinforcing part located respectively between said panels in the area where the handle will be attached with said door panels; and a fireproof material core formed in place between said door panels to produce a real wood like fireproof door.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a fireproof door assembly, and more particularly to a fireproof door assembly having fireproof material filled therein.  
           [0003]    2. Description of the Related Art  
           [0004]    U.S. Pat. No. 5,644,870 is typical of such door structures using two rectangular compression molded skins with each skin having inside surface and outside surface and on its inside surface a plurality of projecting. Parallel ribs along at least two of its edges, a hinge support having a plurality of grooves on its opposite sides with the grooves operable to interlock with the ribs of the skins along one side of the door when the skins are assembled with this support and an accessory support having a plurality of grooves on its opposite sides operable to interlock the ribs of the skins along the other side of the door when the skins are assembled therewith whereby no frame is required for the door when a foamed in place polyurethane core is formed between the skins. The door used interlocking member at its side and top edges and a preformed bottom panel or insert.  
         SUMMARY OF THE INVENTION  
         [0005]    The invention in reference deals with four kinds of fireproof door assembly structures, “flat edge door”, “interlock door”, “intermediate fireproof board” and “double-board fireproof door” structure. The flat edge door structure comprising: two molded door panels of compression molded thin skins overlaid with each other to form door with a hollow core, said skins is flat edge around four sides; A rectangular frame sealing on said door panels operable to flat edge with said frame of the opposing panel when said panels are overlaid with one another; A reinforcing part located respectively between said panels in the area where the handle will be attached with said door panels; and a fireproof material core formed in place between said door panels to produce a real wood like fireproof door. The interlock door having interlocking members on their inner surface. The intermediate fireproof board structure having a fireproof board on the door center. The double-board fireproof door structure having two fireproof boards glue with door panels, and fireproof material filled into door. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    [0006]FIG. 1 is a front view of the flat edge fireproof door pre-hung unit in accordance with the second embodiment of the present invention;  
         [0007]    [0007]FIG. 2 is a front view of the interlock fireproof door pre-hung unit in accordance with a first embodiment of the present invention;  
         [0008]    [0008]FIG. 3 is a section view of the flat edge fireproof door pre-hung unit in accordance with the second embodiment of the present invention;  
         [0009]    [0009]FIG. 4 is a section view of the interlock fireproof door pre-hung unit in accordance with a first embodiment of the present invention;  
         [0010]    [0010]FIG. 5 is a front view of the flat edge fireproof door assembly structure in accordance with the second embodiment of the present invention;  
         [0011]    [0011]FIG. 6 is a front view of the interlock fireproof door assembly structure in accordance with a first embodiment of the present invention;  
         [0012]    [0012]FIG. 7 is a horizontal section view of the flat edge fireproof door assembly structure in accordance with the second embodiment of the present invention;  
         [0013]    [0013]FIG. 8 is a vertical section view of the flat edge fireproof door assembly structure in accordance with the second embodiment of the present invention;  
         [0014]    [0014]FIG. 9 is a horizontal section view of the interlock fireproof door assembly structure in accordance with a first embodiment of the present invention;  
         [0015]    [0015]FIG. 10 is a vertical section view of the interlock fireproof door assembly structure in accordance with a first embodiment of the present invention;  
         [0016]    [0016]FIG. 11 is an exploded perspective view of the flat edge fireproof door assembly structure in accordance with the second embodiment of the present invention;  
         [0017]    [0017]FIG. 12 is an exploded perspective view of the interlock fireproof door assembly structure in accordance with a first embodiment of the present invention;  
         [0018]    [0018]FIG. 13 is a horizontal section view of the intermediate fireproof board door assembly structure in accordance with the third embodiment of the present invention;  
         [0019]    [0019]FIG. 14 is a vertical section view of the intermediate fireproof board door assembly structure in accordance with the third embodiment of the present invention;  
         [0020]    [0020]FIG. 15 is a horizontal section view of the double-board fireproof door assembly structure in accordance with the fourth embodiment of the present invention;  
         [0021]    [0021]FIG. 16 is a vertical section view of the double-board fireproof door assembly structure in accordance with the fourth embodiment of the present invention;  
         [0022]    [0022]FIG. 17 is a manufacturing process view of the phenolic aldyhyde foam. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    The invention in reference deals with four kinds of fireproof door assembly structures, “flat edge door”, “interlock door”, “intermediate fireproof board” and “double-board fireproof door” structure.  
         [0024]    A fireproof door assembly in accordance with the first embodiment of the present invention comprises a first door skin  11 , a second door skin  12 , the top and bottom frame elements  13 ,  14 , the left, right sealing frame material  15 ,  16 , a handle reinforcement material  17 , a fireproof strip  18  (refer to FIG. 1, 3,  5 ,  7 ,  8 ). The thickness of the first door skin  11  and the second door skin  12  is about 1 to 4 mm and the four edges of each door skin are smooth surfaces for tightly adhered to the rectangular frame  13 ,  14 ,  15 ,  16 . The door skins  11  and  12  are made of the material selected from sheet molding compound of glass fiber, wood, and steel. The front surface of the door skins  11 ,  12  can be smooth surface or with wood grain and the backside of the door skins  11  and  12  should be rough surface for increasing the adherence ability. The rectangular frame is made of the material selected from PVC foam profile, wood, steel or injected plastics.  
         [0025]    The assembly sequence of the invention is: the rectangular frame  13 ,  14 ,  15   16  are mounted to the edge of the first door skin  11  by the adhesive, and the reinforcement member  17  is disposed at the lock position to enhance the mechanical strength around the lock potion. Two end of the left frame  15  and the right frame  16  have recessions to receive the end of the top frame  13  and the bottom frame  14  while assembling to form a cabin there between. The bottom frame  14  is then drilled with a hole through which the fireproof material  20  is filled into the cabin. The fireproof material  20  further comprises a hardening agent such that the fireproof material  20  will be solidified in the cabin between the door skins  11  and  12  to block the fire frame. When on fire, the door skins  11 ,  12  will be burn away, however, the fireproof material  20 , including phenol and formaldehyde, will not burn up and thus forms a block wall for the fire.  
         [0026]    The fireproof material  20  mainly comprises phenol and formaldehyde which and mixed to form phenol-formaldehyde resin. The fireproof material  20  further comprises hardening agent, such as acid, vesicant, such as dichloromethane or pentane, and agglutinating agent, such as polyvinyl acetate or magma. The proportion of compound in the fireproof material  20  is as follow:  
         [0027]    Compound 1: 35%˜45% by weight of phenol;  
         [0028]    Compound 2: 35%˜45% by weight of formaldehyde;  
         [0029]    Hardening agent: 10%˜30% by weight of acid;  
         [0030]    Vesicant: 0.01%˜2% by weight of dichloromethane or pentane; and  
         [0031]    Agglutinating agent: 1%˜5% by weight of polyvinyl acetate or magma.  
         [0032]    Refer to FIG. 11, in order to block smock and flame of the fire to flow through a gap between the door and the door jamb, the top frame  13 , the left frame  15  and the right frame  16  have a groove therein so as to receive the fireproof strip  18 . The fireproof strip  18  seals the gap between the door and the door jamb while closing the door.  
         [0033]    A fireproof door assembly in accordance with the second embodiment of the present invention comprises a first door skin  21 , a second door skin  22 , a top reinforcement frame  23 , a bottom frame  14 , a left reinforcement frame  24 , a right reinforcement frame  25 , a handle reinforcement member  17 , a fireproof strip  18  (refer to FIG. 2, 4,  6 ,  9 ,  10 ). The left edge and the right edge of the door skins  21 ,  22  are provided with a rib  26  and a groove  27  resprctively, and the top edge of the door skins  21 ,  22  are provided with another rib  28  and groove  29  respectively. The top reinforcement frame  23 , the bottom frame  14 , the left reinforcement frame  24  and the right reinforcement frame  25  together define a cabin between the edge of the first door skin  21  and the second door skin  22 . The thickness of the first door skin  21  and the second door skin  22  is about 1 to 4 mm and the four edges of each door skin are smooth surfaces for tightly adhered to the rectangular frame  23 ,  14 ,  24 ,  25 . The door skins  21  and  22  are made of the material selected from sheet molding compound of glass fiber, wood, and steel. The front surface of the door skins  21 ,  22  can be smooth surface or with wood grain and the backside of the door skins  21  and  22  should be rough surface for increasing the adherence ability. The rectangular frame is made of the material selected from PVC foam profile, wood, steel or injected plastics.  
         [0034]    The assembly sequence of the invention is: the rectangular reinforcement frame  23 ,  14 ,  24 ,  25  are mounted to the edge of the first door skin  21  by the adhesive, and the reinforcement member  17  is disposed at the lock position to enhance the mechanical strength around the lock potion. The ribs  26 ,  28  are respectively attached to the grooves  27 ,  28  with the adhesive. The bottom frame  14  is then drilled with a hole through which the fireproof material  20  is filled into the cabin. The fireproof material  20  further comprises a hardening agent such that the fireproof material  20  will be solidified in the cabin between the door skins  21  and  22  to block the fire frame. When on fire, the door skins  21 ,  22  will be burn away, however, the fireproof material  20 , including phenol and formaldehyde, will not burn up and thus forms a block wall for the fire.  
         [0035]    The fireproof material  20  mainly comprises phenol and formaldehyde which and mixed to form phenol-formaldehyde resin. The fireproof material  20  further comprises hardening agent, such as acid, vesicant, such as dichloromethane or pentane, and agglutinating agent, such as polyvinyl acetate or magma. The proportion of compound in the fireproof material  20  is as follow:  
         [0036]    Compound 1: 35%˜45% by weight of phenol;  
         [0037]    Compound 2: 35%˜45% by weight of formaldehyde;  
         [0038]    Hardening agent: 10%˜30% by weight of acid;  
         [0039]    Vesicant: 0.01%˜2% by weight of dichloromethane or pentane; and  
         [0040]    Agglutinating agent: 1%˜5% by weight of polyvinyl acetate or magma.  
         [0041]    Refer to FIG. 12, in order to block smock and flame of the fire to flow through a gap between the door and the door jamb, the interlock edge of the door skins  21 ,  22  have a groove therein so as to receive the fireproof strip  18 . The fireproof strip  18  seals the gap between the door and the door jamb while closing the door.  
         [0042]    A fireproof door assembly in accordance with the third embodiment of the present invention to constituting the fireproof door structure, having the fireproof door with an intermediate board featuring: two door skins  11 ,  12 , the top and bottom opposing frame  13 ,  14 , the left, right frame  15 ,  16 , a handle reinforcement material  17 , a fireproof strip  18  and the fireproof board  32  (refer to FIG. 13, 14).  
         [0043]    The door skins  11 ,  12  being of thickness varying between 1-4 mm and the rim in the form of a flat board for successful assembly of the top, bottom, left and right frame  13 ,  14 ,  15 ,  16  in tight bonding. Said sealing rectangular frame material is made of PVC foam profile, wood, or steel.  
         [0044]    The door skins  11 ,  12 , of the invention in question, are made of sheet molding compound, wooden door skin, steel or solid door panels. The coating may be smooth without line or imitation line of depth of between 0.05 to 0.2 mm. Said skin has a rough coating, for additional friction when bonding the door panel.  
         [0045]    Said intermediate partition board  32  is made of oxide magnesium, gypsum or mineral cement, with fireproof properties.  
         [0046]    The assembly sequence of the invention is: first apply glue on the sealing rectangular frame and the door panels with insertion of a reinforcement material at the handle, for additional resistance of the handle when locking; then place 4˜6 small pieces of pad wood in average (of W5 cm*H5 cm*T1.9 cm) on the panel to support the fireproof board  32 . After mounting the fireproof board, place small pieces of pad wood on the fireproof board, to support the door skin of the other side, being the left and right seal duly adapted by means of the ribs and the panels; the upper and lower sealing material are duly positioned by means of the milled upper and lower notch  19  on the left and right sealing material, for forming a concealed and hollow door panel space, before eventually perforating 2 holes on the lower sealing side, on each side of the intermediate partition board  32 . Fill in phenolic aldyhyde foam fireproof substance  20  inside the door.  
         [0047]    A fireproof door assembly in accordance with the fourth embodiment of the present invention. The double-board fireproof door structure comes with: 2 pieces of door skins  11 ,  12 , top and bottom frame  13 ,  14 , left and right frame  15 ,  16 , a handle reinforcement  17 , a smoke strip  18  and a fireproof board  33 ,  34  (refer to FIG. 15, 16).  
         [0048]    The assembly sequence of the double-board fireproof door is: first bond the fireproof board  34  and the door skin  12  together; then bond the fireproof board  33  and the door skin  11  together. Mount the sealing angular materials and the single-sided door panel (glued to the fireproof panel) with glue, with insertion of a reinforcement material to the handle, for additional resistance of the handle when locking. Then place 4˜6 small pieces of pad wood in average (of W5 cm*H5 cm*T3.5 cm) on the fireproof board to support the panel on the other side. Adapt the left and right frame by means of the ribs and the panels; the top and bottom frame are duly positioned by means of the milled top and bottom notch  19 , forming a concealed and hollow door panel space; and eventually perforating 1 hole on the lower sealing side, and fill in phenolic aldyhyde foam fireproof substance  20  inside the door.  
         [0049]    The invention in reference features phenolic aldyhyde foam filled in the fireproof panel, for long-time fireproof performance, requiring a patent.  
         [0050]    An additional description on the phenolic aldyhyde foam is given as follows (refer to FIG. 17):  
         [0051]    The invention in reference has phenolic foam as stuffed material in the fireproof door, for optimal fire-retardant property, low-smoke structure and optimal construction. In case of fire, the optimal fire-retardant property would keep off flame and high temperature, providing safety both people and material, while minimizing loss in material. The low-smoke performance would reduce toxicity or suffocation, for evacuation.  
         [0052]    The stuffing in the fireproof door in the invention in reference is phenolic foam, of 2 liquid or 3 liquid in individual tanks for mixture, before filling for even mixture into the fireproof door for stuffing. The stuffed door is then tightened by a press in a temperature range of 25° C.˜50° C. for 10˜30 minutes, until phenolic foam is fully hardened.  
         [0053]    The phenolic foam of the invention in reference has the following ingredients and preparation:  
         [0054]    The resin used in this invention is a reactive resin of low smoke and optimal fire-retardant property, such as a phenolic foam formed with trioamonium nitride plus urea, in 100 phr. Its preparation may be of 2 liquid or 3 liquid, of which the use and preparation are given in the following:  
         [0055]    Liquid 1: add in 0˜30 phr of (1) water in resin to regulate the viscosity of the resin and control the foaming reaction, and (2) 0.5˜3.0 phr of silicone surfactant to improve the structure of the foam body, for optimal density, using silicone glycol copolymer; (3) phosphorous, nitrogen fire retardant for optimal fireproof property, using ammonium polyphosphate, melamine polyphosphate, pentaerythril, melamine, partial phosphate ester in 0˜30 phr; (4) adding in 1˜12 phr of physical foams, using liquid foam such as HCFC and pentane having a boiling point of between 25° C. ˜80° C.  
         [0056]    Liquid 2: Using hardeners such as mineral acid or irreplaceable sulfuric acid in amount depending on density and acidity and in 2˜60 phr.  
         [0057]    Liquid 3: powder chemical foams of 90° C. ˜140° C. in temperature, of azobisisobutyronitrile, AIBN, diazoamino benzene, benzene sulfonyl hydrazide, p-toluene sulfonyl hydrazide among others in 1˜10 phr. When using chemical foams, add in solvent first to have the powder foams be liquid for successful filling for mixture.  
         [0058]    Preparation and filling of the ingredients in the invention in reference may be of 2 or 3 liquid. The 2-liquid filling is to have the properly mixed liquid 1 and liquid 2 pumped from the ingredient bucket into the 2-liquid high (low) pressure mixer, for a high-speed mixing in the filling machine and filling into the assembled hollow door; the 3-liquid filling differs from the 2-liquid filling mainly by the different foam, using the 2-liquid physical foam and the 3-liquid chemical foam. The 3-liquid filling is to have liquid 1 (without physical foam), liquid 2 and liquid 3 be pumped from the individual bucket into the 3-liquid high (low) pressure mixer, by controlling the dosage and for high-speed mixing in the filling machine before filling into the assembled hollow door, for full hardening of the phenolic foam, before removal.  
         [0059]    The FIG. 17 shows the filling unit of phenolic foam  
         [0060]    (1) Liquid 1 preparation bucket  
         [0061]    (2) Liquid 2 preparation bucket (hardener bucket)  
         [0062]    (3) Liquid 3 preparation bucket (chemical foam bucket)  
         [0063]    (4) Raw material convey metering pump  
         [0064]    (5) Phenolic foam injector  
         [0065]    (6) Phenolic foam filling machine body (refer to Cannon PU foam high/low pressure filling machine similar machines injector for similar units)  
         [0066]    (7) Partition panel