Fiber-reinforced composite fire door
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.
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.