Multi-layered fire door and method for making the same
View Patent ↗A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.
1. A door comprising:
a core comprising a porous layer and at least two fire-retardant layers each having a thickness, wherein the porous layer and the at least two fire-retardant layers are coupled together;
a first exterior layer having a thickness and coupled with the core;
a second exterior layer coupled with the core; and
a grooved first pattern disposed on the first exterior layer and having a first depth, wherein the first depth penetrates the thickness of the first exterior layer and a portion of the thickness of one of the at least two fire-retardant layers.
2. The door according to claim 1 , further comprising a grooved second pattern disposed on the second exterior layer and having a second depth, wherein the second depth penetrates the thickness of the second exterior layer and a portion of the thickness of the other one of the at least two fire-retardant layers.
3. The door according to claim 2 , wherein the first and second depths are about the same.
4. A door comprising:
a porous layer comprising a thermoplastic polymer;
two fire-retardant layers each comprising a fiberboard;
a first exterior layer coupled with one of the fire-retardant layers and a second exterior layer coupled with another one of the fire-retardant layers; and
a first pattern formed in the first exterior layer and having a first depth and a second pattern formed in the second exterior layer having a second depth, wherein the porous layer is coupled with the two fire-retardant layers and the two fire-retardant layers are separated by the porous layer, and wherein the first depth penetrates the first exterior layer and a portion of the one fire-retardant layer.
5. A door comprising:
a porous layer comprising a thermoplastic polymer;
two fire-retardant layers each comprising a fiberboard;
a first exterior layer coupled with one of the fire-retardant layers and a second exterior layer coupled with another one of the fire-retardant layers; and
a first pattern formed in the first exterior layer and having a first depth and a second pattern formed in the second exterior layer having a second depth, wherein the porous layer is coupled with the two fire-retardant layers and the two fire-retardant layers are separated by the porous layer, and wherein the second depth penetrates the second exterior layer and a portion of the another fire-retardant layer.