Fire-resistant composite wood structure particularly adapted for use in fire doors

Claim 2

A fire-resistant wood based structural material comprising: a first layer of material being formed from a slurry mixture of wood chips, ground bark and a fire-retardant chemical that is formed into a board by pressure and drying, a second layer of material being formed from a slurry mixture of individual wood fibers and a fire-retardant chemical that is formed into a board by heat and pressure, said first and second material layers being firmly adhered to each other in their dry states, thereby forming a composite structural material, a third layer of material of the same type and substantially the same thickness as said second layer, said third layer is firmly adhered to said second layer on a side opposite from that adhered to said first layer.

Claim 3

The structural material according to claim 1 wherein said first layer has a thickness of at least several times the thickness of said second layer.

Claim 4

A fire rated door, comprising: a rectangularly-shaped piece of core sheet material having a substantially uniform thickness and edges on all four sides thereof that are planar and perpendicular to major planar surfaces of said core, and composite wood strips attached to at least the opposing edges of said core that are of the longest length, the thickness of said strips being substantially the same as the thickness of the core material, at least one of said strips being formed of a plurality of layers of material, a first layer of material adhered to an edged surface of the core and a second layer of material being adhered to said first layer of material on an opposite side thereof from said core, said first layer of material being thicker than said second layer and being formed from a slurry mixture of wood chips, ground bark and a fire-retardant chemical that is formed into a board by pressure and drying, said second layer of material being formed from a slurry mixture of individual wood fibers and a fire-retardant chemical that is formed into a board by heat and pressure.

Claim 5

A fire rated door, comprising: a rectangularly-shaped piece of core sheet material having a substantially uniform thickness and edges on all four sides thereof that are planar and perpendicular to major planar surfaces of said core, and composite wood strips attached to at least the opposing edges of said core that are of the longest length, the thickness of said strips being substantially the same as the thickness of the core material, at least one of said strips being formed of a plurality of layers of material, a first layer of material adhered to an edged surface of the core and a second layer of material being adhered to said first layer of material on an opposite side thereof from said core, said first layer of material being thicker than said second layer and being formed from a slurry mixture of wood chips, ground bark and a fire-retardant chemical that is formed into a board by pressure and drying, said second layer of material being formed from a slurry mixture of individual wood fibers and a fire-retardant chemical that is formed into a board by heat and pressure.

Claim 6

The fire rated door according to claim 3 wherein the thickness of the core material and its composition, and the thickness of the composite wood edge along said one edge of said core material along with its fire-retardant characteristics are selected to have a fire rating of one and one-half hours or more.

Claim 7

The fire rated door according to claim 3 mounted with said composite wood edge along said one edge of core material being hingedly attached to a door jamb, said jamb including a door stop positioned to be held against said composite wood edge when the door is closed, said door stop having a thickness that is significantly thinner than the combined thickness of said first and second layers of said composite door edge taken in a direction away from the core edge.

Claim 8

The fire rated door according to claim 3 which additionally comprises a composite wood strip extending across the width of the door and dividing said core sheet material into separate upper and lower portions, said composite cross strip having a center board with the same characteristics as first door edge layer with boards adhered on either side thereof to form a smooth surface with opposing surfaces of said core material and that have the same characteristics as said second layer on said composite door edge.

Claim 9

The fire rated door according to any of claims 3, 4, 5 or 6 which additionally comprises facing sheet material attached to the major planar surfaces of said core material as extended by said composite wood edge, thereby to form continuous aesthetically pleasing surfaces on either side.

Claim 10

The fire rated door according to any of claims 3, 4, 5 or 6 wherein said core material consists essentially of a solid mineral material.

Claim 11

The fire rated door according to any of claims 3, 4, 5 or 6 wherein said composite material door edge comprises a third layer of material adhered to said second layer of material on a side opposite to that which is adhered to said first layer.