Fire Rated Door Core With Extruded Frame And Recessed Hardware Mounts
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Solution Overview
Problem
Existing fire rated door manufacturing methods are not well-suited for automated processes, are expensive, and often require additional finishing due to exposed internal mineral cores, which can reduce door strength and complicate panel alignment.
Innovation Solution
A fire rated door core composed of extruded fire resistant material, filler material, and a panel, where the extruded material forms raised portions to accommodate locksets and hinges, with the filler material filling gaps to maintain core thickness, allowing for efficient manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an internal mineral core is used in fire rated doors, then fire resistance capability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The door is divided into distinct components: a simplified core structure, panels, and hardware mounting portions. The core consists of a frame with recesses that receive panels, eliminating the need for complex internal mineral core assemblies while maintaining fire resistance through the panel materials and construction.
Solution Approach 2:
The complex internal mineral core is extracted and replaced with a simpler frame-and-panel construction. The fire resistance function is transferred to the panels and their mounting structure rather than relying on a complex internal core, simplifying manufacturing while maintaining performance.
2Adaptability or versatility
If routed details are added to fire rated doors, then functional features are improved, but the internal mineral core becomes exposed and door strength is reduced
Solution Approach 1:
Hardware mounting portions are nested within recesses in the frame structure. The lockset and hinge mounting portions are integrated into the frame's recesses, allowing functional features to be incorporated without routing through the panels or exposing the core, thereby maintaining door strength.
Solution Approach 2:
The frame structure has localized recesses at specific positions for hardware mounting. These recesses are strategically placed to provide functional features while maintaining the integrity and thickness of the door panels, ensuring door strength is preserved in critical areas.
3Reliability
If panels are assembled with internal mineral core, then fire rating is achieved, but alignment becomes troublesome and additional finishing is required
Solution Approach 1:
The frame structure is pre-configured with recesses and mounting portions before panel installation. Hardware mounting portions are attached to the frame in advance, and the recesses are prepared to receive panels, ensuring proper alignment is achieved during assembly without requiring additional finishing operations.
Solution Approach 2:
The frame structure serves multiple functions: it provides the structural framework, contains recesses for panel reception, incorporates hardware mounting portions, and ensures proper alignment. This multi-functional design simplifies assembly while maintaining fire rating requirements.
4Reliability
If traditional fire rated door construction is used, then fire resistance is achieved, but manufacturing cost and time increase
Solution Approach 1:
The door is segmented into modular components (frame, panels, hardware mounting portions) that can be manufactured separately and assembled efficiently. This modular construction enables parallel manufacturing processes and simplifies quality control, improving overall manufacturing productivity while maintaining fire resistance.
Data Source
AI summary
A core for a fire rated door includes an extruded fire resistant material, a filler material and a panel. The extruded fire resistant material has a first raised portion, a second raised portion and a lower portion that extends from a first end to a second end. The first raised portion has a first thickness and a first width that extends from the first side to the lower portion. The lower portion has a second thickness. The second raised portion has the first thickness and a second width that extends from the second side to the lower portion. The filler material is disposed above the lower portion of the extruded fire resistant material between the first raised portion and the second portion. The panel is attached to the first raised portion and the second raised portion of the extruded fire resistant material and covers the filler material.