Fire door

Claim 2

Edge banding applied to a planar fire door core having a mean plane and planar edge surfaces perpendicular to said mean plane, the edge banding comprising a strip of natural wood, a strip of fiber reinforced thermoset plastic laminate and a strip of a cast gypsum mixture of the following composition: ______________________________________ Weight % of Set and Dried Composition ______________________________________ gypsum dihydrate 65-75 clay 4-5.5 raw vermiculite 4.5-5.5 glass fiber 0.7-1.5 wood chips 5-7 paper fiber 0.8-1.3 (kraft or sulfite) resin binder (solids) 9.5-11.5 dispersant 0.7-1.3 accelerator 0.7-1 defoamer 0.01-0.03 ______________________________________ said cast mixture having a density of at least 60.0 lbs./cu. ft., each of said strips having a pair of oppositely facing surfaces lying in a plane transverse to the mean plane of the fire door core to which the banding is to be affixed, one of said pair of strip surfaces facing inwardly toward the fire foor core edge, the other of said pair of strip surfaces facing outwardly away from the fire door core edge, the inwardly-facing surface of the plastic laminate strip being adhesively fastened to the outwardly surface of the gypsum composition strip, and the outwardly-facing surface of the plastic laminate strip being adhesively fastened to the inwardly-facing surface of the wood strip, the inwardly-facing surface of the gypsum composition strip being presented for fastening along an edge surface of the fire door.

Claim 3

Fire door edge banding as defined in claim 1 wherein said plastic laminate strip comprises thermoset resin material reinforced with kraft paper fibers.

Claim 4

Fire door edge banding as defined in claim 1 wherein said natural wood strip, plastic laminate strip and cast gypsum composition strip have dimensions between the oppositely presented surfaces thereof of the order of about 5/8 inch, 0.05 inch, and 1 inch, respectively.

Claim 5

A fire door for use in a doorway having vertical and horizontal jamb surfaces with a door edge stop positioned inside at least one of the vertical jamb surfaces, the door comprising a planar door core having a mean plane and vertical and horizontal planar edge surfaces perpendicular to said mean plane, and edge banding on at least one of the veritcal edges of the core, the core comprising a slab molded from a fire resistant composition, and the edge banding comprising an assembly of at least three strips, the outermost strip being a strip of natural wood, an intermediate strip being formed of fiber reinforced plastic laminate, and an innermost strip being formed of a cast gypsum composition, said strips having a pair of oppositely presented surfaces transverse to the mean plane of the door core, said edge banding being mounted at an edge of the core with the wood strip positioned outward of the plastic laminate strip, said gypsum composition strip being positioned at the edge of the core, and the plastic laminate strip being positioned between the gypsum composition strip and the wood strip, said wood strip having a thickness in the direction of the mean plane of the core, which thickness is not greater than the depth of the door edge stop inside the jamb surface, so that thermal shielding of at least the wood strip is provided by the door edge strip at the jamb surface of the door.

Claim 6

A fire door for use in a doorway having vertical and horizontal jamb surfaces with a door edge stop positioned inside at least one of the vertical jamb surfaces, the door comprising a planar door core having a mean plane and vertical and horizontal planar edge surfaces perpendicular to said mean plane, and edge banding on at least one of the veritcal edges of the core, the core comprising a slab molded from a fire resistant composition, and the edge banding comprising an assembly of at least three strips, the outermost strip being a strip of natural wood, an intermediate strip being formed of fiber reinforced plastic laminate, and an innermost strip being formed of a cast gypsum composition, said strips having a pair of oppositely presented surfaces transverse to the mean plane of the door core, said edge banding being mounted at an edge of the core with the wood strip positioned outward of the plastic laminate strip, said gypsum composition strip being positioned at the edge of the core, and the plastic laminate strip being positioned between the gypsum composition strip and the wood strip, said wood strip having a thickness in the direction of the mean plane of the core, which thickness is not greater than the depth of the door edge stop inside the jamb surface, so that thermal shielding of at least the wood strip is provided by the door edge strip at the jamb surface of the door.

Claim 7

The fire door of claim 4 wherein a door hinge is fastened to the edge banding, the hinge being positioned in abutting relation to the outwardly facing surface of the wood strip and fastened in place by screws, said hinge-fastening screws penetrating at least into said strip of cast gypsum composition.

Claim 10

A fire door comprising a core and tripartite edge banding, the core having a mean plane and planar edge surface perpendicular to the mean plane of the core and comprising a molded fire-resistant composition having a density of not more than 35 lbs./cu. ft., and the tripartite edge banding comprising a composite of at least three strips comprising a first strip of natural wood, a second strip of fiber reinforced thermoset plastic laminate, and a third strip of a cast mixture of the following ingredients in the weight percentages indicated: ______________________________________ Weight % of Set and Dried Composition ______________________________________ gypsum dihydrate 65-75 clay 4-5.5 raw vermiculite 4.5-5.5 glass fiber 0.7-1.5 wood chips 5-7 paper fiber 0.8-1.3 (kraft or sulfite) resin binder (solids) 9.5-11.5 dispersant 0.7-1.3 accelerator 0.7-1 defoamer 0.01-0.03 ______________________________________ said cast mixture having a density of from about 60 to about 75 lbs./cu. ft., each of said strips having a pair of oppositely presented surfaces transverse to the mean plane of said core, one of said strip surfaces facing inwardly toward the core edge, the other of said strip surfaces facing outwardly away from the core edge, the inwardly-facing surface of the plastic laminate strip being adhesively fastened to the outwardly-facing surface of the gypsum composition strip, the outwardly-facing surface of the plastic laminate strip being adhesively fastened to the inwardly facing surface of the wood strip, and the inwardly-facing surface of the gypsum composition strip being mounted against at least one core edge.

Claim 11

A fire door comprising a core and tripartite edge banding, the core having a mean plane and planar edge surface perpendicular to the mean plane of the core and comprising a molded fire-resistant composition having a density of not more than 35 lbs./cu. ft., and the tripartite edge banding comprising a composite of at least three strips comprising a first strip of natural wood, a second strip of fiber reinforced thermoset plastic laminate, and a third strip of a cast mixture of the following ingredients in the weight percentages indicated: ______________________________________ Weight % of Set and Dried Composition ______________________________________ gypsum dihydrate 65-75 clay 4-5.5 raw vermiculite 4.5-5.5 glass fiber 0.7-1.5 wood chips 5-7 paper fiber 0.8-1.3 (kraft or sulfite) resin binder (solids) 9.5-11.5 dispersant 0.7-1.3 accelerator 0.7-1 defoamer 0.01-0.03 ______________________________________ said cast mixture having a density of from about 60 to about 75 lbs./cu. ft., each of said strips having a pair of oppositely presented surfaces transverse to the mean plane of said core, one of said strip surfaces facing inwardly toward the core edge, the other of said strip surfaces facing outwardly away from the core edge, the inwardly-facing surface of the plastic laminate strip being adhesively fastened to the outwardly-facing surface of the gypsum composition strip, the outwardly-facing surface of the plastic laminate strip being adhesively fastened to the inwardly facing surface of the wood strip, and the inwardly-facing surface of the gypsum composition strip being mounted against at least one core edge.

Claim 12

The fire door of claim 7 wherein the tripartite edge banding is fastened to at least vertically disposed edges of the core.

Claim 13

Edge banding according to claim 1 and having a screw holding capacity of about 500 to about 750 lbs.

Claim 14

Edge banding according to claim 1 in which the banding comprises a wood strip, a plastic strip and a composition strip having dimensions between the oppositely presented surfaces thereof of the order of about 1/2 inch, 0.05 inch and 1 inch, respectively, and having a screw holding capacity on the order of about 740 lbs.

Claim 15

Edge banding according to claim 1 in which the several ingredients of the cast gypsum mixture are used in the neighborhood of about the following percentages: ______________________________________ Weight % of Set and Dried Composition ______________________________________ gypsum dihydrate 68 clay 5 raw vermiculite 5 glass fiber 1 wood chips 6 paper fiber 1 (kraft or sulfite) resin binder (solids) 11 dispersant 1 accelerator 1 defoamer trace ______________________________________