AU2008203033B2

AU2008203033B2 - A fire resistant door and door set

Info

Publication number: AU2008203033B2
Application number: AU2008203033A
Authority: AU
Inventors: Bob Coutts
Original assignee: Assa Abloy Australia Pty Ltd
Current assignee: Assa Abloy Australia Pty Ltd
Priority date: 2007-07-10
Filing date: 2008-07-09
Publication date: 2015-02-12
Anticipated expiration: 2028-07-09
Also published as: SG149760A1; AU2008203033A8; AU2008203033B8; AU2008203033A1; NZ569720A

Abstract

This invention relates to a fire retardant door set 1 including a door 2 located in an opening defined by a jamb 3. The door 2 includes a frame 4 formed from framing elements including a top rail 5, a bottom rail 6, a lock style 7 and an in 5 style 8. The top rail 5, bottom rail 6, lock style 7 and in-style 8 being a manufactured composition combining cellulose material, intumescent material and a binder so that when the frame is heated each element expands at the edges of the door to engage a jamb. V:\sharon'brdcComm LetteAbstrect 200790372e - BjuS doc

Description

P/00/01 1 Regulation 3.2 AUSTRALIA Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title: A FIRE RESISTANT DOOR AND DOOR SET Applicant: ASSA ABLOY Australia Pty Limited The following statement is a full description of this invention, including the best method of performing it known to me: 1 0087 TC 2 A Fire Resistant Door and Door Set This invention relates to a fire resistant door and door set. The invention 5 has a particular application for resisting fire from moving through an opening defined by a jamb, when the opening is obstructed by the fire resistant door. It will be convenient to hereinafter describe the invention with reference to this particular application, however it is to be appreciated that the invention is not limited to this application. 10 A door set is the combination of a door and a door jamb that surrounds the door or surrounds at least the side edges and top edge of the door. Where the door is a panel door it will often include a frame, also referred to in industry as an edge strip, made from dressed timber. The frame is formed by a top rail, a lock stile connected to the top rail for receiving a lock or latch mechanism, an in 15 stile also connected to the top rail which is positioned on an opposing side of the door from the lock stile, and a bottom rail connected to both stiles at the base of the door. A panel may be located within the frame, or a pair of panels may overlie and be spaced apart by the thickness of the frame thereby leaving a hollow core. 20 Where the door set is required to act as a fire resistant door set, one solution is to attach a thin strip of intumescent composition around the perimeter of the frame. When a fire occurs, the intumescent material chars and expands when exposed to the heat so as to engage the jamb surrounding the frame. This effectively seals the gap between the frame and the jamb, retarding the 25 passage of fire and or smoke between the door and the jamb. The frame is often formed with a rebate formed around the perimeter to accommodate the strip. The strip is normally attached or adhered to the frame. This adds a number of steps to the manufacturing process and therefore the cost of the door. 30 Doors in general often require altering, as the jamb or door may not be squarely installed, or with time the shape of the door or jamb may warp. One V .hrn\bra\Prvsonals\ASSA - A Firo Rsiwt o and Dowr Sol 6Jul7.doc 3 solution is to plane or shave the edge of the door to reduce one or more dimensions so as to fit within the dimensions of the opening defined by the jamb. Where an intumescent strip is attached to the edge of the door it is not possible to plane edge as it may adversely affect the ability of the strip to react 5 to the heat, expanding to occupy the gap as required. A fire retardant door will normally be delivered to site with the strip attached. When on site it will be necessary to fit the lock to the lock stile and hinges to the in stile. It may be preferred that a mortice lock is fitted, in which case the strip will be cut on site on the lock stile. The hinges will also need to be 10 fitted to the in stile so again the strip may be cut. The strip needs to be cut with a high degree of precision in order to minimise the gaps between the strip and the lock or hinge. It is an object of this invention to provide a fire retardant door that addresses one or more of the above problems. It is desirable for the door to be 15 relatively easy to manufacture. It is also desirable for the door to be capable of being altered. The above discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any of 20 these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed in Australia before the priority date of this invention. According to one aspect of this invention there is provided a fire retardant door for retarding fire from moving through an opening defined by a jamb when 25 the opening is obstructed by the door, the door includes, a frame formed from framing elements including a top rail at a top edge of the door, a bottom rail at a bottom edge of the door and a pair of stiles on opposing side edges of the door connected to the top and bottom rail, the top rail, bottom rail and stiles forming the external edges of the door, the top rail, bottom rail and stiles being a 30 manufactured composition being formed by combining a mixture of cellulose material, intumescent material and being bound together by a pair of panels ASSA - A Fire Resistant Door and Door Set 6jul07 4 attached to the frame and extending towards the edges of the door frame, the panels presenting opposing faces of the door, a vermiculite between the pair of opposing panels wherein when the frame is heated each element expands at the edges of the door to engage the jamb to seal the opening 5 thereby retarding movement of fire through the opening. It is further preferred that the or each panel is a manufactured composition combining cellulose material, intumescent material and a binder. It is preferred that the intumescent material is located in each framing element from the edge to substantially 50% of the thickness of the framing 10 element. It is preferred that the manufactured composition includes 3% to 12% of intumescent material by weight. It is further preferred that the intumescent material is graphite. It is further preferred that the cellulose material is selected from any one or more of paper, wood flour, wood fibre and medium density fibre 15 (MDF). It is further preferred that the binder is a resin selected from any one or more of an acrylic polymer, or phenol-formaldehyde. It is further preferred that the manufactured composition includes 15% to 20% binder by weight. According to another aspect of this invention there is provided a fire retardant door set including a door and a jamb for retarding fire from moving 20 through an opening defined by the jamb when the opening is obstructed by a door, the door includes, a frame formed from framing elements including a top rail at a top edge of the door, a bottom rail at a bottom edge of the door and a pair of stiles on opposing side edges of the door connected to the top and bottom rail, the top rail, bottom rail and stiles forming the external edges of the 25 door, the jamb is formed from jamb elements includes a strike jamb positioned adjacent the lock stile, a top jamb connected to the strike jamb positioned adjacent the top rail, and a hinge jamb positioned adjacent the in stile, when the door obstructs the opening a gap is left between the frame and the jamb, the framing elements and or the jamb elements are a manufactured composition 30 being formed by combining a mixture of cellulose material, intumescent material ASSA - A Fire Resistant Door and Door Set 6jul07 4a and being bound together by a binder, a pair of panels attached to the frame and extending towards the edges of the door frame, the panels presentingopposing faces of the door, a vermiculite between the pair of opposing panels wherein when the frame and or jamb is heated the frame and 5 or jamb element ASSA - A Fire Resistant Door and Door Set 6jul07 5 expands into the gap to seal the opening thereby retarding movement of fire through the opening. It is preferred that the gap is less than 25mm. It is further preferred that the gap at the top rail, in stile or lock stile is less than the gap at the bottom rail. 5 It is still further preferred that the gap at the top rail, in stile or lock stile is less than 8mm, while the gap at the bottom rail is less than 20mm. The jamb may be formed from metal and the frame is formed from the manufactured composition. Alternatively the jamb may be formed from the manufactured composition and the frame is formed from timber. A further 10 alternative is for the jamb and the frame to be formed from the manufactured composition. It will be convenient to hereinafter describe the invention in greater detail by reference to the accompanying drawings showing two example embodiments of the invention. The particularity of the drawings and the related 15 detailed description is not to be understood as superseding the generality of the broad definition of the invention. Figure 1 is a schematic front elevation of a preferred embodiment of a door set according to one aspect of this invention. 20 Figure 2 is a cross sectional detail through A-A of figure 1 with a metal jamb. Figure 3 is a cross sectional detail through A-A of figure 1 with a cellulose jamb. Referring firstly to figure 1 which illustrates a door set 1 including a door 25 2 located in an opening defined by a jamb 3. The door 2 includes a frame 4 formed from framing elements. The framing elements illustrated include a top rail 5 located at an upper edge of the door 2, a bottom rail 6 located at a bottom edge of the door 2 and a lock stile 7 and in stile 8 on opposing side edges of the door 2 connecting the top 5 and bottom 6 rails. The in stile 8 accommodates the 30 hinges 9 while the lock stile 7 accommodates the lock 10. The frame 4 may V .sharonbad\Provisinals\ASSA - A Fire Resistant Door and Door Sol 6jl07 doc 6 include further framing elements such as a mid rail (not shown) however this is not essential to the invention. The jamb 3 may be separated into corresponding jamb element 5 including a top jam 11, a lock jamb 12 and a hinge jamb 13. A bottom jamb (not 5 illustrated) may also be included however it is not essential for a fire retardant door set to include a bottom jamb. The door 2 is illustrated in a closed position revealing a gap 14 between the door 2 and the jamb 3. The size of the gap 14 illustrated has been exaggerated for ease of identification, however the gap 14 is generally less than 10 5 mm on the side and top edges of the door. The gap 14 at the bottom edge of the door may be as great as 20mm to allow for variations in floor coverings from carpet to concrete or the like. The gap 14 allows the door 2 to swing open and closed unimpeded by the jamb 3, however the gap 14 needs to be sealed in the event of a fire. 15 Referring now to figure 2, which illustrates a first preferred embodiment of the door set 1 including a metal jamb 3 with a fire retardant door 2. In this embodiment the door frame 4 is a manufactured composition combining a cellulose material, intumescent material and a binder. A pair of panels 15,16 are attached to and spaced by the frame 4 to provide a front and rear surface of the 20 door 2. The panels 15,16 may be made from the same or similar manufactured composition as the frame 4. The space defined by the frame and the panels is occupied by a vermiculite material 17 or other fire retardant material. Referring now to figure 3, which illustrates a second preferred embodiment of the invention including a jamb 3 formed from a manufactured 25 composition with a fire retardant door 2. In this embodiment the jamb 3 is a manufactured composition combining a cellulose material, intumescent material and a binder. The frame 4 may also be formed from the manufactured composition, or alternatively they may be formed from timber or metal (not shown). A pair of panels 15,16 are attached to and spaced by the frame 4 to 30 provide a front and rear surface of the door. The panels may be made from the same or similar manufactured composition. The space defined by the frame 4 V :harnbadiProvisonals\ASSA - A Fre Resstant Door and Door Sol 6ul7.doc 7 and the panels 15,16 is occupied by a vermiculite material 17 or other fire retardant material. The manufactured composition preferably includes 3% to 12% intumescent material by weight, and the preferred intumescent material is 5 graphite. The intumescent material may be limited to the edge region of the jamb or frame element that in use is to be positioned adjacent the gap 14. The size of the edge region may, for example, be 50% of the thickness of the frame or jamb element. This may vary depending on the requirements of the door set. The cellulose material may include one or more of the following 10 materials, paper, wood flour, wood fibre and medium density fibre(MDF). The cellulose material may be combined with the intumescent material in a dry form, and mixed with the binder. It is preferred that the binder be 15% to 20% by weight, however this may vary. The binder may be any suitable binder however an acrylic polymer or phenol-formaldehyde has been found suitable. The 15 mixture can then be placed in a form and pressurised to form a component that can be machined to produce the frame or jamb element. It will be appreciated that by having the intumescent material extending through the frame or jamb element, allows the element to be cut, shaved or planed while maintaining the fire retardant and structural qualities of the 20 element. In particular the intumescent material in the frame or jamb element will still char when exposed to heat, thereby occupying the gap 14. Various alterations, additions or modifications may be made to the preferred embodiment as herein before described without departing from the spirit or ambit of the invention as defined in the attached claims. V :\h obrad onalsASSA - A Fire Reastant Door and Door Set ju07.dOC

Claims

1. A fire retardant door for retarding fire from moving through an opening defined by a jamb when the opening is obstructed by the door, the door 5 includes, a frame formed from framing elements including a top rail at a top edge of the door, a bottom rail at a bottom edge of the door and a pair of stiles on opposing side edges of the door connected to the top and bottom rail, the top rail, bottom rail and stiles forming the external edges of the door, the top rail, bottom rail and stiles being a manufactured composition being formed by 10 combining a mixture of cellulose material, intumescent material and being bound together by a binder, a pair of panels attached to the frame and extending towards the edges of the door frame, the panels presenting opposing faces of the door, a vermiculite between the pair of opposing panels wherein when the frame is heated each element expands at the edges of the door to 15 engage the jamb to seal the opening thereby retarding movement of fire through the opening.

2. A fire retardant door according to claim 1 wherein the or each panel is a manufactured composition combining cellulose material, intumescent material and a binder. 20

3. A fire retardant door according to any one of the preceding claims wherein the intumescent material is located in each framing element from the edge to substantially 50% of the thickness of the framing element.

4. A fire retardant door according to wherein the composition includes 3% to 12% of intumescent material by weight. 25

5. A fire retardant door according to any one of the preceding claims wherein the intumescent material is graphite.

6. A fire retardant door according to any one of the preceding claims wherein the cellulose material is selected from any one or more of paper, wood flour, wood fibre and medium density fibre(MDF). ASSA - A Fire Resistant Door and Door Set 6jul07 9

7. A fire retardant door according to any one of the preceding claims wherein the binder is a resin selected from any one or more of an acrylic polymer, or phenol-formaldehyde.

8. A fire retardant door according to any one of the preceding claims 5 wherein the composition includes 15% to 20% binder by weight.

9. A fire retardant door set including a door and a jamb for retarding fire from moving through an opening defined by the jamb when the opening is obstructed by a door, the door includes, a frame formed from framing elements including a top rail at a top edge of the door, a bottom rail at a bottom edge of 10 the door and a pair of stiles on opposing side edges of the door connected to the top and bottom rail, the top rail, bottom rail and stiles forming the external edges of the door, the jamb is formed from jamb elements includes a strike jamb positioned adjacent the lock stile, a top jamb connected to the strike jamb positioned adjacent the top rail, and a hinge jamb positioned adjacent the in 15 stile, when the door obstructs the opening a gap is left between the frame and the jamb, the framing elements and or the jamb elements are a manufactured composition being formed by combining a mixture of cellulose material, intumescent material and being bound together by a binder, a pair of panels attached to the frame and extending towards the edges of the door frame, the 20 panels presenting opposing faces of the door, a vermiculite between the pair of opposing panels wherein when the frame and or jamb is heated the frame and or jamb element expands into the gap to seal the opening thereby retarding movement of fire through the opening.

10. A fire retardant door set according to claim 9 wherein the gap is less than 25 25mm.

11. A fire retardant door set according to claim 9 or 10 wherein the gap at the top rail, in stile or lock stile is less than the gap at the bottom rail.

12. A fire retardant door set according to claim 11 wherein the gap at the top rail, in stile or lock stile is less than 8mm, while the gap at the bottom rail is less 30 than 20mm. ASSA - A Fire Resistant Door and Door Set 6jul07 10

13. A fire retardant door set according to any one of claims 9 to 12 wherein the jamb is formed from metal and the frame is formed from the manufactured composition.

14. A fire retardant door set according to any one of claims 9 to 12 wherein 5 the jamb is formed from the manufactured composition and the frame is formed from timber.

15. A fire retardant door set according to any one of claims 9 to 12 wherein the jamb and the frame are formed from the manufactured composition.

16. A fire retardant door set according to any one of claims 9 to 15 10 incorporating a fire door according to any one of claims 1 to 8. ASSA - A Fire Resistant Door and Door Set 6jul07