RU2641872C2 - Gypsum composites used in fire-resistant building elements - Google Patents

Abstract

FIELD: fire safety.

SUBSTANCE: composite product contains gypsum in the amount of 60-90 wt %, fibre in the amount of 1.5-26 wt %, essentially, uniformly distributed in the composite, and rheology modifier in the amount of 0.5-6 wt %. The composite is cured or allowed to solidify to form a cured composite. The cured composite is a fire-resistant element used in a fire-resistant core of a door, a fire-resistant door or a fire-resistant structural panel. The fire-resistant element may be a structural panel, a door panel, a door core, a door rail, a door stile, a door lock, a door frame or a door insert.

EFFECT: increased fire resistance.

52 cl, 30 dwg

Description

FIELD OF THE INVENTION

The present invention relates to the field of composite materials and, in particular, to gypsum composites used in flame retardant building materials.

BACKGROUND AND BACKGROUND OF THE INVENTION

After a long time, many methods and technologies for manufacturing fireproof doors have been developed. However, it should be noted that most of these known designs are not suitable for fully automated manufacturing processes. In addition, the well-known fire-resistant doors are expensive and require an internal mineral core. The inner core may be open in curly details and may reduce the strength of the door due to the reduced thickness of the door panel. In addition, alignment of the panels during assembly may be difficult and require additional decoration to square the door after assembly.

Cement-based composites have been used in building materials for many years. For example: US Pat. cement-based composites, the disclosures of which are hereby incorporated by reference in their entirety. However, these patents and published applications do not disclose flame retardant composites with the necessary flame retardant properties for the manufacture of doors, door cores and building panels that can be certified fire resistant.

SUMMARY OF THE INVENTION

Elements from fire-resistant composites with the necessary fire-resistant abilities are proposed for the manufacture of doors, door cores and building panels that can receive fire resistance certification. In most cases, the length and width of the fire-resistant core of the door will meet the technical conditions for the finished door product in terms of length and width. The dimensions of the fireproof door core will typically be three and four feet (approximately 0.6 - 1.2 m) in width and seven to ten feet (approximately 2.1 - 3.0 m) in length. The thickness of the flame retardant core can vary from 1.50 to 2.00 inches (3.81 and 5.08 cm, respectively). In some cases, an outer strapping may be added to the sides and ends of the fireproof core of the door. In other cases, an intumescent fire retardant may be added between the outer trim and the fireproof core of the door.

In particular, a composite product is proposed comprising gypsum in an amount of 60 to 90 mass. %, fiber in an amount of 1.5 to 26 mass. %, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5 to 6 mass. % The composite is cured or allowed to cure to form a cured composite. A cured composite is a fire resistant element used in the fireproof core of a door, fireproof door, or fireproof building panel. The fire-resistant element may be a building panel, door panel, door core, horizontal door trim block, vertical door trim block, door lock block, door border or door insert.

In addition, a composite product is proposed containing gypsum in an amount of 60 to 85 mass. %, fiber in an amount of 1.5 to 5 mass. %, essentially uniformly distributed over the composite, aggregate in an amount of 10 to 25 mass. %, essentially uniformly distributed over the composite, starch in an amount of 2 to 7 mass. % and rheology modifier in an amount of 0.5 to 4 mass. % The composite is cured or allowed to cure to form a cured composite. The fire-retardant element can be a building panel, door panel, door core, horizontal door trim block, vertical door trim block, door lock block, door border or door insert used in a fireproof door core, fireproof door, or fireproof building panel.

In addition, a composite product is proposed containing gypsum in an amount of 60 to 90 mass. %, fiberglass in an amount of 2 to 10 mass. %, essentially uniformly distributed over the composite, cellulose fiber in an amount of 2 to 8 mass. %, essentially uniformly distributed over the composite, polyvinyl alcohol fibers in an amount of 1 to 4 mass. %, essentially uniformly distributed over the composite, polypropylene fibers in an amount of 0.3 to 4 mass. %, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5 to 6 mass. % The composite is cured or allowed to cure to form a cured composite. The fire-resistant element can be a building panel, door panel, door core, horizontal door trim block, vertical door trim block, door lock block, door frame or door insert used in a fireproof door core, fireproof door, or fireproof building panel.

In addition, a core for a fireproof door is provided, comprising a fireproof central web and an extruded fireproof frame. The fire resistant central web has a lower surface, an upper surface, a first side, a second side, a first end and a second end. Fire-resistant central fabric is made of the first fire-resistant material containing gypsum in the amount of 60 - 85 mass. %, fiber in an amount of 1.5 to 5 mass. %, essentially uniformly distributed over the composite, aggregate in an amount of 10 to 25 mass. %, essentially uniformly distributed over the composite, starch in an amount of 2 to 7 mass. % and rheology modifier in an amount of 0.5 to 4 mass. % The extruded fire-resistant frame is adapted to be attached to the first side, second side, first end and second end of the fire-resistant central web. Extruded fire-resistant frame is made of a second fire-resistant material containing gypsum in the amount of 60 - 90 mass. %, fiberglass in an amount of 2 to 10 mass. %, essentially uniformly distributed over the composite, cellulose fiber in an amount of 2 to 8 mass. %, essentially uniformly distributed over the composite, polyvinyl alcohol fibers in an amount of 1 to 4 mass. %, essentially uniformly distributed over the composite, polypropylene fibers in an amount of 0.3 to 4 mass. %, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5 to 6 mass. %

In addition, a fire resistant door is provided comprising a core, a first decorative panel and a second decorative panel. The core contains: (a) a fire-resistant central fabric having a lower surface, upper surface, a first side, a second side, a first end and a second end, wherein the fire-resistant central fabric is made of a first fire-resistant material containing gypsum in an amount of 60 to 85 mass. %, fiber in an amount of 1.5 to 5 mass. %, essentially uniformly distributed over the composite, aggregate in an amount of 10 to 25 mass. %, essentially uniformly distributed over the composite, starch in an amount of 2 to 7 mass. % and rheology modifier in an amount of 0.5 to 4 mass. %, and (b) an extruded fire-resistant frame attached to the first side, second side, first end and second end of the fire-resistant central fabric, and the extruded fire-resistant frame is made of a second fire-resistant material containing gypsum in an amount of 60 to 90 mass. %, fiberglass in an amount of 2 to 10 mass. %, essentially uniformly distributed over the composite, cellulose fiber in an amount of 2 to 8 mass. %, essentially uniformly distributed over the composite, polyvinyl alcohol fibers in an amount of 1 to 4 mass. %, essentially uniformly distributed over the composite, polypropylene fibers in an amount of 0.3 to 4 mass. %, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5 to 6 mass. % The first decorative panel is made with the possibility of attaching to the upper surface of the fire-resistant central fabric and extruded fire-resistant frame. The second decorative panel is made with the possibility of attaching to the lower surface of the fire-resistant central canvas and extruded fire-resistant frame.

The following is a detailed description of the present invention with reference to the accompanying drawings.

A brief description of the graphic material

The above and additional advantages of the invention can be better understood by referring to the following description with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a core for a fireproof door in accordance with one embodiment of the present invention;

FIG. 2 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 3A to 3D are cross-sectional views of various mating surfaces of a central web and a door core frame in accordance with one embodiment of the present invention;

FIG. 4 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 5 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 6 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 7 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 8 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 9 is a perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 10A is an exploded perspective view of a core for a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 10B is a sectional view of the door core of FIG. 10A;

FIG. 11A is a perspective view of a fireproof door in accordance with one embodiment of the present invention;

FIG. 11B is a section through the fireproof door of FIG. 11A;

FIG. 11C is a sectional view of an alternative fireproof door of FIG. 11A;

FIG. 12A is an exploded perspective view of a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 12B is a section through the fire door of FIG. 12A;

FIG. 13A is an exploded perspective view of a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 13B is a section through the fire door of FIG. 13A;

FIG. 13C is a sectional view of an alternative fireproof door of FIG. 13A;

FIG. 14A is an exploded perspective view of a fireproof door in accordance with yet another embodiment of the present invention;

FIG. 14B is a section through the fireproof door of FIG. 14A;

FIG. 14C is a sectional view of an alternative fireproof door of FIG. 14A;

FIG. 15A is an exploded perspective view of a fire door in accordance with yet another embodiment of the present invention;

FIG. 15B is a section through the fire door of FIG. 5A;

FIG. 16 is a flowchart of a method for manufacturing a core for a fire door in accordance with one embodiment of the present invention;

FIG. 17 is a flowchart of a method for manufacturing a core for a fireproof door in accordance with yet another embodiment of the present invention; and

FIG. 18 is a flowchart of a method for manufacturing a core for a fire door in accordance with yet another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Although the manufacture and use of various embodiments of the present invention are described in detail below, it should be understood that there are many applicable ideas of the invention that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are purely illustrative of specific ways of making and using the invention and do not limit the scope of the invention. The discussion in the present description relates mainly to fire resistant doors, however, it is clear that the ideas of the present invention are applicable to any type of door.

The proposed composite product provides fire-resistant elements with the necessary fire-resistant abilities for the manufacture of doors, door cores and building panels that can receive fire resistance certification. The composite contains gypsum in an amount of 60 to 90 mass. %, fiber in an amount of 1.5 to 26 mass. %, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5 to 6 mass. % Gypsum can be 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75% , 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90 mass. %, or other intermediate percentage. Fibers can be 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5%, 7% , 7.5%, 8%, 8.5%, 9%, 9.5%, 10%, 10.5%, 11%, 11.5%, 12%, 12.5%, 13%, 13 , 5%, 14%, 14.5%, 15%, 15.5%, 16%, 16.5%, 17%, 17.5%, 18%, 18.5%, 19%, 19.5 %, 20%, 20.5%, 21%, 21.5%, 22%, 22.5%, 23%, 23.5%, 24%, 24.5%, 25%, 25.5% or 26 mass. %, or other intermediate percentage. The fibers may be fiberglass, cellulose fiber, polyvinyl alcohol fibers, polypropylene fibers, or a combination thereof. Other types of fibers may be used. The rheology modifier may be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4 %, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3, 5%, 3.6%, 3.7%, 3.8%, 3.9%, 4%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5% , 4.6%, 4.7%, 4.8%, 4.9%, 5%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5 , 6%, 5.7%, 5.8%, 5.9% or 6 mass. %, or other intermediate percentage. The rheology modifier may be methyl hydroxypropyl cellulose (MPHC), methyl hydroxyethyl cellulose (MPH), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC). Other types of rheology modifier may be used.

The composite is cured or allowed to cure to form a cured composite. The actual component weights used will depend on the density required for the flame retardant. A cured composite is a fire resistant element used in the fireproof core of a door, fireproof door, or fireproof building panel. The fire-resistant element may be a building panel, door panel, door core, horizontal door trim block, vertical door trim block, door lock block, door border or door insert. The flame retardant element typically has a cross section thickness of 0.125 - 2 inches (0.32 - 5.08 cm), a width of 1 inch - 4 feet (2.54 - 122 cm) and a length of 3 - 10 feet (91 - 305 cm). In addition, and unlike many known composite materials, the proposed composite product does not contain cement or fly ash.

The proposed door core provides the fire resistance required to obtain the necessary certifications. The length and width of the fire-resistant core will meet the technical specifications for the finished door product in terms of length and width. The dimensions of the fireproof door core will typically be three and four feet (approximately 0.6 - 1.2 m) in width and seven to ten feet (approximately 2.1 - 3.0 m) in length. The core thickness of the door will usually be between 0.125 and 1.5 inches (0.32 and 3.8 cm, respectively). The door manufacturer may use any of the prefabricated core designs described herein as the fireproof core of the fireproof door of that manufacturer. The resulting fireproof door can have fire resistance limits of 20 - 30, 45, 60, 90 or 120 minutes depending on the design and materials used. The manufacturer will typically finish the finished door product by adding wood or veneer to the door to provide an aesthetic appeal to the product.

Turning now to FIG. 1, which is a perspective view of a core 100 for a fire door in accordance with one embodiment of the present invention. The core 100 comprises a flame retardant central web 102 and an extruded flame retardant frame 104. The flame retardant central web 102 has a lower surface (not shown), upper surface 106, a first side 108, a second side 110, a first end 112 and a second end 114. The fire resistant central web 102 is made from the first fire-resistant material, which can be either bulk or extrudable. The first flame retardant material may consist of gypsum, water, glass, ceramic material, cellulose or fibrous material and one or more binders. One example of such a material in accordance with the present invention is given below:

First flame retardant material Component Limits (wt.%) Gypsum 60 - 85 Fiberglass 1,5 - 5 Lightweight placeholder 10 - 25 Starch 2 - 7 Rheology modifier 0.5 - 4 Vermiculite or clay 0-10

Gypsum can be 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75% , 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84% or 85 mass. %, or other intermediate percentage. Glass fiber can be 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5% or 5 mass. %, or other intermediate percentage. Fiberglass may have a diameter of 6 to 25 mm. Lightweight aggregate can be 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24% or 25 mass %, or other intermediate percentage. Lightweight aggregate, such as Poraver ^® porous glass beads, can have average particle diameters of 1–2 mm or 2–4 mm. Starch can be 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5% or 7 wt. %, or other intermediate percentage. Starch is pregelatinized or custard starch. The rheology modifier may be cellulose ether, such as methyl hydroxypropyl cellulose (MHPC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC), carboxymethyl cellulose (CMC), or similar materials. The rheology modifier may be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4 %, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3, 5%, 3.6%, 3.7%, 3.8%, 3.9% or 4 wt. %, or other intermediate percentage. The composition may also include vermiculite or clay in the amount of 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9% or 10 mass. %, or other intermediate percentage. As is clear to those skilled in the art, other materials may be used in return.

The extruded flame-retardant frame 104 is made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second flame-retardant material has a holding capacity (for example, fasteners will adhere to the second flame-retardant material and remain fixed after installation) and can be molded using extrusion process. One example of such a material in accordance with the present invention is given below:

Second flame retardant material Component Limits (wt.%) Gypsum 60 - 90 Fiberglass 2 - 10 Cellulose fiber 2 - 8 Polyvinyl alcohol fiber fourteen Polypropylene fiber 0.3 - 4 Rheology modifier 0.5 - 6

Gypsum can be 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75% , 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90 mass. %, or other intermediate percentage. Glass fiber can be 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5% , 8%, 8.5%, 9%, 9.5% or 10 mass. %, or other intermediate percentage. Fiberglass may have a diameter of 6 to 25 mm. Cellulose fiber can be 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5 % or 8 mass. %, or other intermediate percentage. The cellulosic fiber may be hardwood or softwood. Polyvinyl alcohol fibers can be 1%, 1.5%, 2%, 2.5%, 3%, 3.5% or 4 wt. %, or other intermediate percentage. Polyvinyl alcohol fibers can have a diameter of 6-10 mm with a decitex of approximately 15. Polypropylene fibers can be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1, 1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1% , 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3 , 2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9% or 4 wt. %, or other intermediate percentage. Polypropylene fibers can have a diameter of 6 - 25 mm. The rheology modifier may be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4 %, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3, 5%, 3.6%, 3.7%, 3.8%, 3.9%, 4%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5% , 4.6%, 4.7%, 4.8%, 4.9%, 5%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5 , 6%, 5.7%, 5.8%, 5.9% or 6 mass. %, or other intermediate percentage. The rheology modifier may be cellulose ether, such as methyl hydroxypropyl cellulose (MHPC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC), carboxymethyl cellulose (CMC), or similar materials. As is clear to those skilled in the art, other materials may be used in return.

The extruded fire-resistant frame 104 may be made of a molded part from a second fire-resistant material (for example, Fig. 1) or vertical and horizontal bars of the door trim made of a second fire-resistant material, glued or bonded (for example, Fig. 4). The extruded flame retardant frame 104 is adapted to attach to the first side 108, second side 110, first end 112, and second end 114 of the flame retardant central web 102 using glue, fasteners, or a bonding process (for example, pouring the first flame retardant material into a “mold” formed extruded flame retardant frame 104). A few examples of the mating surface between the extruded flame retardant frame 104 and the flame retardant central web 102 are shown in FIG. 3A - 3D.

The physical dimensions of the core 100 and other cores described below with reference to FIG. 2-10A and B, the flame retardant central web 102 and the extruded flame retardant frame 104 will vary depending on the particular application for which the door core is being manufactured. Typical dimensions may include, but are not limited to, a thickness of 1.5 to 2.0 inches (3.81 and 5.08 cm, respectively) of the flame retardant web 102 and the extruded flame retardant frame 104, total length 7 to 10 feet (213 to 305 cm) of a core 100, a total width of 3 to 4 feet (91 to 122 cm) of a core 100, a width of 1 to 5 inches (2.5 to 12.7 cm) of the upper and lower parts (horizontal bars) of an extruded fire-resistant frame 104, and a width 1 to 5 inches (2.5 to 12.7 cm) (e.g., 1.625 inches (4.13 cm)) of the left and right parts (vertical bars) of the extruded fire-resistant frame 104.

Core 100 and other cores described below with reference to FIG. 2-10A and B can be made by assembling the fire-resistant frame 104, pouring the first fire-resistant material into the zone formed by the fire-resistant frame 104, and sintering the core 100. Alternatively, the core 100 can be made by creating sheets of the first fire-resistant material and the second fire-resistant material with using the extrusion process, cutting onto slats of sheets of the second fire-resistant material for the manufacture of vertical and horizontal bars of the fire-resistant frame, finishing extruded vertical and horizontal br Skov to the desired profile, or trimming them to the required smoothness, size and shape and bonding or fastening vertical and horizontal bars of the frame to a fire resistant fireproof central web 102.

Turning now to FIG. 2, which is a perspective view of a core 200 for a fireproof door in accordance with yet another embodiment of the present invention. The core 200 comprises a first fire-resistant central fabric 102a, a second fire-resistant central fabric 102b and an extruded fire-resistant frame 104. The first fire-resistant central fabric 102a has a lower surface (not shown), upper surface 106a, first side 108a, second side 110a, first end 112 and second end 202. The second fire-resistant central fabric 102b has a lower surface (not shown), an upper surface 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire-resistant central fabric 102a and the second fire oykoe central web 102b made of a first fireproof material, which may be either self-leveling or extruded. The extruded flame-retardant frame 104 is made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second flame-retardant material has a holding capacity (for example, fasteners will adhere to the second flame-retardant material and remain fixed after installation) and can be molded using extrusion process. In addition, the extruded flame retardant frame 104 comprises a central horizontal bar 206 made of a second flame retardant material. The extruded fire-resistant frame 104 may be made of a molded part from a second fire-resistant material (for example, Fig. 2) or vertical and horizontal bars of the door trim made of a second fire-resistant material, glued or bonded (for example, Fig. 5). The extruded fire-resistant frame 104 (including the center horizontal bar 206) is adapted to be attached to the first side 108a, the second side 110a, the first end 112a and the second end 202 of the fire-resistant central fabric 102a and the first side 108b, the second side 110b, the first end 204 and the second end 114 of the second flame-retardant central web 102b using glue, fasteners, or a bonding process (for example, pouring the first flame-retardant material into a “mold” formed by an extruded flame-retardant frame 104). A few examples of the mating surface between the extruded flame retardant frame 104 and the flame retardant central webs 102a, 102b are shown in FIG. 3A - 3D.

The physical dimensions of the core 200 and other cores described below with reference to FIG. 3-10A and B, the fire-resistant central panels 102a, 102b and the extruded fire-resistant frames 104 will vary depending on the particular application for which the door core is being manufactured. Typical dimensions may include, but are not limited to, a thickness of 1.5 inches (3.8 cm) of flame retardant sheets 102a, 102b and extruded flame retardant frame 104, total length 7 to 10 feet (213 to 305 cm) of core 100, total width 3 - 4 feet (91 to 122 cm) of core 100, 1 to 5 inches wide (2.5 to 12.7 cm) of the upper, lower and central parts (horizontal bars) of the extruded fire-resistant frame 104, and 1 to 5 inches wide (2 5 - 12.7 cm) (e.g., 1.625 inches (4.13 cm)) of the left and right parts (vertical bars) of the extruded fire-resistant frame 104.

Turning now to FIG. 3A-3D, showing cross-sections of various mating surfaces of the central web 102 and the frame 104 of the door core 100, 200, 400, 500, 600, 700, 800 and 900 in accordance with one embodiment of the present invention. In FIG. 3A shows a straight mating surface in which glue is used to secure the extruded fire-resistant frame 104 to the fire-resistant center web 102. It should be noted that the straight mating surface may be at an angle to the upper surface of the flame retardant central web 102 instead of extending substantially perpendicularly. As shown in FIG. 3B-3D, the extruded fire-resistant frame 104 can be attached to the fire-resistant central fabric 102 by a set of male-female connectors 302, 304, 306 made in the extruded fire-resistant frame 104 and the fire-resistant central fabric 102. The male-female connectors may be triangular in shape 302 (FIG. 3B), curved shape 304 (Fig. 3C) or 306 (Fig. 3D), rectangular, angled, sheet pile or a combination thereof. Adhesive is used to attach the extruded flame retardant frame 104 to the flame retardant central web 102, but fasteners or bonding processes may also be used.

Turning now to FIG. 4, which is a perspective view of a core 400 for a fireproof door in accordance with yet another embodiment of the present invention. The core 400 comprises a flame retardant central web 102 and an extruded flame retardant frame 104. The flame retardant central web 102 has a lower surface (not shown), an upper surface 106, a first side 108, a second side 110, a first end 112 and a second end 114. The fire resistant central web 102 is made from the first fire-resistant material, which can be either bulk or extrudable. The extruded fire-resistant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper) and a second horizontal bar 408 (lower). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second the flame retardant material has a holding capacity (for example, fasteners will adhere to the second flame retardant material and remain fixed after installation) and can be molded using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are glued or bonded together and with a fire-resistant central fabric 102. The first vertical bar 402 (left) configured to attach to the first side 108 of the flame retardant central web 102 using glue, fasteners, or a bonding process. The second vertical bar 404 (right) is adapted to be attached to the second side 110 of the flame retardant central web 102 using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to be attached to the first end 112 of the flame retardant central web 102 using glue, fasteners, or a bonding process. The second horizontal bar 408 (upper) is adapted to be attached to the second end 114 of the flame retardant central web 102 using glue, fasteners, or a bonding process. A few examples of the mating surface between the vertical bars 402, 404, the horizontal bars 406, 408 and the fire-resistant central web 102 are shown in FIG. 3A - 3D.

Turning now to FIG. 5, which is a perspective view of a core 500 for a fireproof door in accordance with yet another embodiment of the present invention. The core 500 comprises a first fire-resistant central fabric 102a, a second fire-resistant central fabric 102b and an extruded fire-resistant frame 104. The first fire-resistant central fabric 102a has a lower surface (not shown), upper surface 106a, first side 108a, second side 110a, first end 112a and second end 202. The second fire-resistant central fabric 102b has a lower surface (not shown), an upper surface 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire-resistant central fabric 102a and the second fire the tough central web 102b is made of a first flame-retardant material, which can be either bulk or extrudable. The extruded flame retardant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper), a second horizontal bar 408 (lower), and a third horizontal bar or insert 502 (central). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower) and the third horizontal bar or insert 502 (central) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second flame-retardant material has a holding capacity (for example, fasteners will adhere to the second flame-retardant material and remain fixed after installation) and may MOV using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower), the Third horizontal bar or insert 502 (central) are glued or bonded to each other and with fire-resistant central webs 102a and 102b. The first vertical bar 402 (left) is configured to adhere to the first side 108a, 108b of the fire resistant central webs 102a, 102b using glue, fasteners, or a bonding process. The second vertical bar 404 (right) is adapted to attach to the second side 110a, 110b of the fire-resistant central webs 102a, 102b using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to attach to the first end 112 of the first flame-retardant central web 102a using glue, fasteners or a bonding process. The second horizontal bar 408 (lower) is adapted to attach to the second end 114 of the second flame-retardant central web 102b using glue, fasteners, or a bonding process. The third horizontal bar or insert 502 (central) is configured to attach to the second end 202 of the first fire-resistant central fabric 102a and the first end 204 of the second fire-resistant central fabric 102b using glue, fasteners or a bonding process. A few examples of the mating surface between the vertical bars 402, 404, the horizontal bars 406, 408 and the fire-resistant central webs 102a, 102b are shown in FIG. 3A - 3D. These mating surfaces can also be used between the fire resistant central webs 102a, 102b and the third horizontal bar or insert 502 (central).

Turning now to FIG. 6, which is a perspective view of a core 600 for a fire door in accordance with yet another embodiment of the present invention. The core 600 comprises a flame retardant central web 102, an extruded flame retardant frame 104 and a lock block 602. The fire resistant central web 102 has a lower surface (not shown), upper surface 106, first side 108, second side 110, first end 112, second end 114 and cut or a recess 604 located in the first flank 108. The fire-resistant central web 102 is made of a first fire-resistant material, which can be either bulk or extrudable. The lock block 602 is located in the cutout or recess 604 of the fire-resistant central web 102. The lock block 602 is made of a second fire-resistant material and dimensioned to accommodate the door handle, locking device or other door fittings. The extruded fire-resistant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper) and a second horizontal bar 408 (lower). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second the flame retardant material has a holding capacity (for example, fasteners will adhere to the second flame retardant material and remain fixed after installation) and can be molded using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are glued or bonded to each other and to the fire-resistant central fabric 102 and the locking block 602. The first vertical bar 402 (left) is configured to attach to the first side 108 of the flame retardant central web 102 and the locking block 602 using glue, fasteners, or a bonding process. The second vertical bar 404 (right) is adapted to be attached to the second side 110 of the flame retardant central web 102 using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to be attached to the first end 112 of the flame retardant central web 102 using glue, fasteners, or a bonding process. The second horizontal bar 408 (upper) is adapted to be attached to the second end 114 of the flame retardant central web 102 using glue, fasteners, or a bonding process. A few examples of the mating surface between the vertical bars 402, 404, the horizontal bars 406, 408 and the fire-resistant central web 102 are shown in FIG. 3A - 3D. These mating surfaces can also be used between the locking block 602, the fire-resistant central web 102 and the first vertical bar 402 (left).

Turning now to FIG. 7, which is a perspective view of a core 700 for a fire door in accordance with yet another embodiment of the present invention. The core 700 comprises a first fire-resistant central fabric 102a, a second fire-resistant fabric 102b and an extruded fire-resistant frame 104. The first fire-resistant central fabric 102a has a lower surface (not shown), upper surface 106a, first side 108a, second side 110a, first end 112a and second end 202. The second fire-resistant central fabric 102b has a lower surface (not shown), an upper surface 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire-resistant central fabric 102a and the second fire-resistant center the webs 102b are made of a first flame-retardant material, which may be either bulk or extrudable. The extruded flame retardant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper), a second horizontal bar 408 (lower) and a third horizontal bar or insert 702 (middle). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower) and the third horizontal bar or insert 702 (middle) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second flame-retardant material has a holding capacity (for example, fasteners will adhere to the second flame-retardant material and remain fixed after installation) and may tsya using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower), the third horizontal bar or insert 702 (middle) are glued or bonded to each other and with fireproof central webs 102a and 102b. The first vertical bar 402 (left) is configured to adhere to the first side 108a, 108b of the fire resistant central webs 102a, 102b using glue, fasteners, or a bonding process. The second vertical bar 404 (right) is adapted to attach to the second side 110a, 110b of the fire-resistant central webs 102a, 102b using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to attach to the first end 112 of the first flame-retardant central web 102a using glue, fasteners or a bonding process. The second horizontal bar 408 (lower) is adapted to attach to the second end 114 of the second flame-retardant central web 102b using glue, fasteners, or a bonding process. The third horizontal bar or insert 702 (middle) is configured to attach to the second end 202 of the first fire-resistant central fabric 102a and the first end 204 of the first fire-resistant central fabric 102b using glue, fasteners or a bonding process. A third horizontal bar or insert 702 (middle) is positioned and dimensioned (for example, 5 to 10 inches wide (12.7 to 25.4 cm) to accept various fixtures, such as an emergency rod. A few examples of the mating surface between the vertical bars 402, 404, horizontal bars 406, 408, and fire-resistant central webs 102a, 102b are shown in Figures 3A-3D, These mating surfaces can also be used between the fire-resistant central webs 102a, 102b and the third horizontal bar or insert 702 (middle).

Turning now to FIG. 8, which is a perspective view of a core 800 for a fireproof door in accordance with yet another embodiment of the present invention. The core 800 comprises a first fire-resistant central fabric 102a, a second fire-resistant central fabric 102b, an extruded fire-resistant frame 104 and a locking block 602. The first fire-resistant central fabric 102a has a lower surface (not shown), upper surface 106a, first side 108a, second side 110a, first an end 112a, a second end 202, and a cutout or recess 604 located in the first side 108a. The second fire-resistant central fabric 102b has a lower surface (not shown), an upper surface 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire-resistant central fabric 102a and the second fire-resistant central fabric 102b are made of the first fire-resistant material, which can be either bulk or extrudable. The locking block 602 is located in the cutout or recess 604 of the first fire-resistant central web 102a. The locking block 602 is made of a second fire-resistant material and is dimensionally designed to accommodate the door handle, locking device or other door fittings. The extruded flame retardant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper), a second horizontal bar 408 (lower) and a third horizontal bar or insert 702 (middle). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower) and the third horizontal bar or insert 702 (middle) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second flame-retardant material has a holding capacity (for example, fasteners will adhere to the second flame-retardant material and remain fixed after installation) and may tsya using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper), the second horizontal bar 408 (lower), the third horizontal bar or insert 702 (middle) are glued or bonded to each other and with fireproof central webs 102a, 102b and locking block 602. The first vertical bar 402 (left) is adapted to be attached to the first side 108a, 108b of the fireproof central webs 102a, 102b and locking block 602 using glue, fasteners, or a bonding process. The second vertical bar 404 (right) is adapted to attach to the second side 110a, 110b of the fire-resistant central webs 102a, 102b using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to attach to the first end 112 of the first flame-retardant central web 102a using glue, fasteners or a bonding process. The second horizontal bar 408 (lower) is adapted to attach to the second end 114 of the second flame-retardant central web 102b using glue, fasteners, or a bonding process. The third horizontal bar or insert 702 (middle) is adapted to attach to the second end 202 of the first fire-resistant central web 102a, the first end 204 of the second fire-resistant central web 102b and the locking block 602 using glue, fasteners or a bonding process. A third horizontal bar or insert 702 (middle) is positioned and dimensioned (for example, 5 to 10 inches wide (12.7 to 25.4 cm) to accept various fixtures, such as an emergency rod. A few examples of the mating surface between the vertical bars 402, 404, horizontal bars 406, 408 and fire-resistant central webs 102a, 102b are shown in Figures 3A-3D. These mating surfaces can also be used between the locking block 602, fire-resistant central webs 102a, the first vertical bar 402 (left) and the third horizontal bar com or insert 702 (average).

Turning now to FIG. 9, which is a perspective view of a core 900 for a fire door in accordance with yet another embodiment of the present invention. The core 900 comprises a central web 902 and an extruded fire-resistant frame 104. The central web 902 has a lower surface (not shown), an upper surface 106, a first side 108, a second side 110, a first end 112 and a second end 114. The central web 902 is made of corrugated filler (e.g. cardboard, etc.) that has several voids (e.g. honeycomb, hexagonal, triangular, etc.) and can be filled with soundproofing material (e.g. fiberglass, foam, etc.). The extruded fire-resistant frame 104 is made of a first vertical bar 402 (left), a second vertical bar 404 (right), a first horizontal bar 406 (upper) and a second horizontal bar 408 (lower). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second the flame retardant material has a holding capacity (for example, fasteners will adhere to the second flame retardant material and remain fixed after installation) and can be molded using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are glued or fastened together and with the central canvas 902. The first vertical bar 402 (left) is made with the possibility of attaching to the first side 108 of the Central canvas 902 using glue, fasteners or the bonding process. The second vertical bar 404 (right) is adapted to be attached to the second side 110 of the central web 902 using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is adapted to be attached to the first end 112 of the central web 902 using glue, fasteners, or a bonding process. The second horizontal bar 408 (upper) is adapted to be attached to the second end 114 of the central web 902 using glue, fasteners, or a bonding process. A few examples of the mating surface between the vertical bars 402, 404, the horizontal bars 406, 408 and the fire-resistant central web 902 are shown in FIG. 3A - 3D. It should be noted that the central blade 902 alone is not suitable for forming a fireproof door. In order to make a fireproof door, fireproof materials or panels must be installed on the upper surface 106 and the lower surface (not shown) of the central web 902. For example, a central blade 902 may be used in doors 1100 (FIG. 11A), 1200 (FIG. 12A), and 1300 (FIG. 13A) if the panels 1102, 1102, and 1302 are respectively made of a flame-retardant material (for example, a second fire-resistant material and etc.).

Turning now to FIG. 10A showing an exploded perspective view of a core 1000 for a fire door in accordance with yet another embodiment of the present invention. The core 1000 comprises a flame retardant central web 102 or 1002 located between the upper insulating panel 902a and the lower insulating panel 902b, and an extruded fire-resistant frame 104 around three panels 902a, 102 (or 1002) and 902b. The fire resistant central web 102 is made of a first fire resistant material, which can be either bulk or extrudable. The fire resistant central web 1002 is made of a second fire resistant material, which can be either bulk or extrudable. The upper insulation panel 902a and the lower insulation panel 902b are made of corrugated filler (e.g. cardboard, etc.) having several voids (e.g. honeycomb, hexagonal, triangular, etc.) and may be filled with soundproofing material (e.g. , fiberglass, foam, etc.). The three panels 902a, 102 (or 1002) and 902b are usually glued together. The flame retardant central web 102 or 1002 has a lower surface (not shown), an upper surface 106, a first side 108, a second side 110, a first end 112 and a second end 114. The extruded fire resistant frame 104 is made of a first vertical bar 402 (left), a second vertical a bar 404 (right), a first horizontal bar 406 (upper) and a second horizontal bar 408 (lower). The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are made of a second flame-retardant material having a higher density than the first flame-retardant material, while the second the flame retardant material has a holding capacity (for example, fasteners will adhere to the second flame retardant material and remain fixed after installation) and can be molded using an extrusion process. The first vertical bar 402 (left), the second vertical bar 404 (right), the first horizontal bar 406 (upper) and the second horizontal bar 408 (lower) are glued or fastened together and with three panels 902a, 102 (or 1002) and 902b. The first vertical bar 402 (left) is configured to attach to the first side 108 of three panels 902a, 102 (or 1002) and 902b using glue, fasteners, or a bonding process. the second vertical bar 404 (right) is configured to attach to the second side 110 of three panels 902a, 102 (or 1002) and 902b using glue, fasteners, or a bonding process. The first horizontal bar 406 (upper) is configured to attach to the first end 112 of three panels 902a, 102 (or 1002) and 902b using glue, fasteners, or a bonding process. The second horizontal bar 408 (upper) is configured to attach to the second end 114 of the three panels 902a, 102 (or 1002) and 902b using glue, fasteners, or a bonding process. A few examples of the mating surface between the vertical bars 402, 404, the horizontal bars 406, 408, and the fire-resistant central web 102 are shown in FIG. 3A - 3D. FIG. 10B is a sectional view of the door core of FIG. 10A.

It should be noted that the cores shown in FIG. 1 to 10A and B and described above may also include a top panel attached to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, or a lower panel attached to the bottom surface of the core 100 , 200, 300, 400, 500, 600, 700, 800, 900 or 1000, or both panels (upper and lower) attached to the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 An example of such a construction is shown in FIG. 13A and 14A. The top panel or the bottom panel may be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, fireproof panel, one or more protective layers, or a combination thereof. One or more of the protective layers may be a flame retardant material, an explosive resistant material, a bulletproof material, a shielding material, a chemically resistant material, a biohazard resistant material, a radiation resistant material, a moisturizing material, a grounding material, an insulating material, or a combination thereof. For example, one or more protective layers can be one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of polyurethane foam, a layer of graphite, a wire mesh or their combination. In addition, the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, and / or the upper or lower panels may and / or may be covered with intumescent or fireproof material. Finally, it should be noted that the horizontal bars shown in the figures can extend to the sides of the door or core so that the vertical bars extend between the upper and lower horizontal bars.

Turning now to FIG. 11A, an exploded perspective view of a fire door core 1100 in accordance with yet another embodiment of the present invention. The fireproof door 1100 comprises a core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (for more details see Figs. 1-10A and B and the associated description), a first decorative panel 1102 and a second decorative panel 1104. The first and second decorative panels 1102 and 1104 can be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, flame retardant, or a combination thereof. The first decorative panel 1102 is configured to be attached to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with glue. The second decorative panel 1104 is adapted to be attached to the lower surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with glue. It should be noted that the glue may have flame retardant properties or be an intumescent material. The first and second decorative panels 1102 and 1104 are slightly larger in length and width to form a space for accommodating an outer strapping 1106 attached to each side and end of a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000. The outer strapping 1106 may be a first strapping 1106a, a second strapping 1106b, a third strapping 1106c and a fourth strapping 1106d. FIG. 11B is a section through a fireproof door 1100. In FIG. 11C shows a section through an alternative embodiment of a fireproof door 1100, in which an intumescent material 1108 may also be located between the outer trim 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000.

Turning now to FIG. 12A, an exploded perspective view of a core 1200 for a fire door in accordance with yet another embodiment of the present invention. Fire-resistant door 1200 contains a core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (for more details see Figs. 1-10A and B, and the associated description), the first decorative panel 1102 and the second decorative panel 1104. The first and second decorative panels 1102 and 1104 may be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, flame retardant, or a combination thereof. It should be noted that the first and second decorative panels 1102 and 1104 may also have flame retardant properties. The first decorative panel 1102 is configured to be attached to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with glue. The second decorative panel 1104 is adapted to be attached to the lower surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with glue. It should be noted that the glue may have flame retardant properties or be an intumescent material. The first and second decorative panels 1102 and 1104 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. As a result, additional strapping, horizontal bars and vertical strands not required. FIG. 12B is a section through a fireproof door 1200.

Turning now to FIG. 13A, an exploded perspective view of a fire door core 1300 in accordance with yet another embodiment of the present invention. The fireproof door 1300 comprises a core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (for more details see Figs. 1-10A and B and the associated description), a first protective panel or layer 1302 ( also referred to as a top panel), a first decorative panel 1102, a second protective panel or layer 1304 (also referred to as a lower panel) and a second decorative panel 1104. The first protective panel or layer 1302 and the second protective panel or layer 1304 may be flame retardant, flameproof material , bulletproof material, shielding material, chemically resistant material resistant biohazard material, radiation-resistant material, moisturizing material, ground material, an insulating material or a combination thereof. For example, the first protective panel or layer 1302 and the second protective panel or layer 1304 may be one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer polyurethane foam, a layer of graphite, wire mesh or a combination thereof. A fire-resistant door with a fire resistance of 120 minutes can be obtained by using a dense fire-resistant material, such as a second fire-resistant material, such as the first and second protective panels or layers 1302 and 1304. The first and second decorative panels 1102 and 1104 can be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, flame retardant, or a combination thereof. The first decorative panel 1102 is configured to adhere to the upper surface of the first protective panel or layer 1302 with glue. The first protective panel or layer 1302 is configured to adhere to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with glue. The second decorative panel 1104 is configured to adhere to the bottom surface of the second protective panel or layer 1304 with glue. The second protective panel or layer 1304 is adapted to be attached to the lower surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 with glue. It should be noted that the glue may have flame retardant properties or be an intumescent material. The first and second decorative panels 1102, 1104, and the first and second protective panels or layers 1302, 1304 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000. As a result, additional strapping, horizontal bars and vertical strapping bars are not required. FIG. 13B is a section through a fireproof door 1300. FIG. 13C is a cross-sectional view of an alternative fire door 1300, in which the first and second decorative panels 1102 and 1104 are slightly longer and wide to form a space for the outer strapping 1106 attached to each side and end of the core 100, 200, 300, 400, 500 , 600, 700, 800, 900 or 1000. As shown in FIG. 11A, outer strapping 1106 may be a first strapping 1106a, a second strapping 1106b, a third strapping 1106c, and a fourth strapping 1106d. In addition, an alternative fireproof door 1300 may be manufactured in which an intumescent material 1108 may also be located between the outer trim 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (see FIG. 11C).

Turning now to FIG. 14A, an exploded perspective view of a fire door core 1400 in accordance with yet another embodiment of the present invention. The fireproof door 1400 comprises a core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (for more details see Figs. 1-10A and B and the associated description), a first insulating panel or layer 1402, the first decorative panel 1102, the second insulation panel or layer 1404 and the second decorative panel 1104. The first insulation panel or layer 1402 and the second protective panel or layer 1404 are made of corrugated filler (e.g. cardboard, etc.) having several voids (e.g. , honeycomb, hexagonal, triangular, etc.) filled with insulating and / or flame oykim material (e.g., fiberglass, foam, and so on. d.). The first and second decorative panels 1102 and 1104 may be a lignocellulosic backing, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, flame retardant, or a combination thereof. The first decorative panel 1102 is configured to adhere to the upper surface of the first insulating panel or layer 1402 with glue. The first insulating panel or layer 1402 is adapted to be attached to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 with glue. The second decorative panel 1104 is configured to adhere to the bottom surface of the second insulating panel or layer 1404 with glue. The second insulation panel or layer 1404 is adapted to be attached to the lower surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 with glue. It should be noted that the glue may have flame retardant properties or be an intumescent material. The first and second decorative panels 1102, 1104 and the first and second insulation panels or layers 1402, 1404 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000. As consequence, additional strapping, horizontal bars and vertical strapping bars are not required. FIG. 14B is a section through a fire door 1400. In FIG. 14C is a cross-sectional view of an alternative fire door 1400 in which the first and second decorative panels 1102 and 1104 are slightly longer and wide to form a space for accommodating an outer strapping 1106 attached to each side and end of a core 100, 200, 300, 400, 500 , 600, 700, 800, 900 or 1000. As shown in FIG. 11A, outer strapping 1106 may be a first strapping 1106a, a second strapping 1106b, a third strapping 1106c, and a fourth strapping 1106d. In addition, an alternative fireproof door 1400 may be manufactured in which an intumescent material 1108 may also be located between the outer trim 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (see FIG. 11C).

Turning now to FIG. 15A, an exploded perspective view of a fire door core 1500 in accordance with yet another embodiment of the present invention. Fire-resistant door 1500 contains a core of 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (for more details see Fig. 1 - 10 and the associated description), the first decorative panel 1102, the second decorative panel 1104 and four horizontal bars 1502. Alternatively, the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 may be a single sheet of flame retardant material, including without limitation the first flame retardant material. The rear side of the first and second decorative panels 1102 and 1104 has a recess or cutout 1504 along the left and right sides, the size of which or which corresponds to each horizontal bar 1502. Each horizontal bar 1502 is made of a second flame-retardant material or other suitable material. In one example, the horizontal bars are 11/16 inches high and 1 inch wide (1.77 and 2.54 cm, respectively). The first and second decorative panels 1102 and 1104 may be a lignocellulosic substrate, wood, a wooden composite, medium density fiberboard, high density fiberboard, particleboard, masonite. It should be noted that the first and second decorative panels 1102 and 1104 may also be flame retardant properties. The first decorative panel 1102 is adapted to be attached to the upper surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or a single sheet of fire-resistant material with glue. The second decorative panel 1104 is configured to be attached to the lower surface of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or a single sheet of fire-resistant material with glue. It should be noted that the glue may have flame retardant properties or be an intumescent material. The first and second decorative panels 1102 and 1104 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, or a single sheet of flame retardant material. As a result, additional strapping, horizontal bars and vertical strapping bars are not required. FIG. 15B is a section through a fireproof door 1500.

Turning now to FIG. 16, a flowchart of a method 1600 for manufacturing a core for a fire door in accordance with one embodiment of the present invention is shown. At a block 1602, a flame retardant central web having a lower surface, an upper surface, a first side, a second side, a first end and a second end is taken, the fire resistant central web being made of a first fire resistant material. At a block 1604, a first vertical bar of an extruded flame retardant frame is attached to the first side of the flame retardant central web, wherein the extruded flame retardant frame is made of a second flame retardant material having a higher density than the first flame retardant material. At a block 1606, a second vertical bar of an extruded flame retardant frame is attached to the second side of the flame retardant central web. At a block 1608, a first horizontal bar of the extruded flame retardant frame is fastened to the first end of the flame retardant central web and the first vertical bar and second vertical bar of the extruded flame retardant frame. At a block 1610, a second horizontal bar of the extruded flame retardant frame is secured to a second end of the flame retardant center web and a first vertical bar and a second vertical bar of the extruded flame retardant frame. The optional step may include forming a fireproof door by attaching the first decorative and second decorative panels to the upper surface and lower surface of the fireproof central canvas, the first vertical bar, the second vertical bar, the first horizontal bar and the second horizontal bar of the extruded frame in block 1612. Additional elements as described with reference to FIG. 11 to 15A and B. Another optional step may include coating the flame retardant core web and the extruded flame retardant frame with intumescent or flame retardant material. It should be noted that method 1600 can be performed as part of a continuous manufacturing process.

In one embodiment, a recess is created in the first side of the flame-retardant central web, a fire-resistant lock block is inserted into the recess, and the fire-resistant lock block is attached to the fire-resistant central canvas and the extruded fire-resistant frame, wherein the fire-resistant lock block is made of a second fire-resistant material. In another embodiment, the flame retardant central fabric comprises: (a) a first flame resistant central fabric located between the first side and the second side near the first end, the first flame resistant central fabric made of a first flame resistant material; (b) a second fire-resistant central fabric located between the first side and the second side near the second end, the second fire-resistant central fabric made of the first fire-resistant material; and (c) a fire-resistant insert located between the first fire-resistant central fabric and the second fire-resistant central fabric and attached to them and passing between the extruded fire-resistant frame on the first side and the second side and attached to it, and the fire-resistant material is made of a second fire-resistant material. In yet another embodiment, a set of male-female connectors are provided in an extruded fire-resistant frame and a fire-resistant central web. The male-female connectors may be triangular, curved, rectangular, angled, sheet pile, or a combination thereof.

In yet another embodiment, the first flame-retardant material is extruded or cast to form a flame-retardant central web, and the second flame-retardant material is extruded or cast to form a first vertical bar, a second vertical bar, a first horizontal bar and a second horizontal bar of an extruded fire-resistant frame. In yet another embodiment, the first flame-retardant material is extruded or cast to form a flame-retardant central web, and the second flame-retardant material is extruded or cast to form a sheet, which is then cut into slats to form one or more of the first vertical bar, second vertical bar, first horizontal bar and a second horizontal bar of extruded flame retardant frame. In any embodiment, panels, vertical bars, and horizontal bars can go through one or more finishing steps (e.g. sandblasting, trimming, cutting, removing sharp tips trapped in the surface finish layer, etc.) so that the parts have the proper smoothness , size and shape.

In addition, the upper panel can be attached to the upper surface of the fire-resistant central fabric and extruded fire-resistant frame, or the lower panel can be attached to the lower surface of the fire-resistant central fabric, or both panels (upper and lower) can be attached to the fire-resistant central fabric. The top panel or the bottom panel may be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, one or more protective layers, or a combination thereof. One or more of the protective layers may be a flame retardant material, an explosive resistant material, a bulletproof material, a shielding material, a chemically resistant material, a biohazard resistant material, a radiation resistant material, a moisturizing material, a grounding material, an insulating material, or a combination thereof. For example, one or more protective layers can be one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of polyurethane foam, a layer of graphite, a wire mesh or their combination.

Turning now to FIG. 17, which shows a flow diagram of a method 1700 for manufacturing a core for a fireproof door in accordance with yet another embodiment of the present invention. At a block 1702, an extruded flame retardant frame is taken. The extruded fire-resistant frame has a central void and is made by taking the first vertical bar of the extruded fire-resistant frame, attaching the first horizontal bar of the extruded fire-resistant frame to the first vertical bar, attaching the second horizontal bar to the extruded fire-resistant frame to the first vertical bar and attaching the second vertical bar to the vertical horizontal bar and second horizontal bar extruded a flame retardant frame, wherein the extruded flame retardant frame is made of a second flame retardant material. At a block 1704, a void in an extruded flame-retardant frame is filled with a first flame-retardant material having a lower density than the second flame-retardant material to form a flame-retardant central web. At a block 1706, the extruded flame retardant frame and the first flame retardant material are baked or cured to set and fix the material. After that, sandblasting or other finishing steps can be performed. An optional step may include forming a fire door by attaching the first decorative and second decorative panels to the upper and lower surfaces of the extruded fire resistant frame and the fire resistant central web in block 1708. Additional elements may be added as described with reference to FIG. 11 to 15. An optional step may include coating the flame retardant central web and the extruded flame retardant frame with intumescent or flame retardant material. It should be noted that method 1700 can be performed as part of a continuous manufacturing process.

In one embodiment, a recess is created in the first side of the flame-retardant central web, a fire-resistant lock block is inserted into the recess, and the fire-resistant lock block is attached to the fire-resistant central canvas and the extruded fire-resistant frame, wherein the fire-resistant lock block is made of a second fire-resistant material. In another embodiment, the flame retardant central fabric comprises: (a) a first flame resistant central fabric located between the first side and the second side near the first end, the first flame resistant central fabric made of a first flame resistant material; (b) a second fire-resistant central fabric located between the first side and the second side near the second end, the second fire-resistant central fabric made of the first fire-resistant material; and (c) a fire-resistant insert located between the first fire-resistant central fabric and the second fire-resistant central fabric and attached to them and passing between the extruded fire-resistant frame on the first side and the second side and attached to them, and the fire-resistant material is made of a second fire-resistant material. In yet another embodiment, a set of male-female connectors are provided in an extruded fire-resistant frame and a fire-resistant central web. The male-female connectors may be triangular, curved, rectangular, angled, sheet pile, or a combination thereof.

In yet another embodiment, the first flame-retardant material is extruded or cast to form a flame-retardant central web, and the second flame-retardant material is extruded or cast to form a first vertical bar, a second vertical bar, a first horizontal bar and a second horizontal bar of an extruded fire-resistant frame. In yet another embodiment, the first flame-retardant material is extruded or cast to form a flame-retardant central web, and the second flame-retardant material is extruded or cast to form a sheet, which is then cut into slats to form one or more of the first vertical bar, second vertical bar, first horizontal bar and a second horizontal bar of extruded flame retardant frame.

In addition, the upper panel can be attached to the upper surface of the fire-resistant central fabric and extruded fire-resistant frame, or the lower panel can be attached to the lower surface of the fire-resistant central fabric, or both panels (upper and lower) can be attached to the fire-resistant central fabric. The top panel or the bottom panel may be a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, one or more protective layers, or a combination thereof. One or more of the protective layers may be a flame retardant material, an explosive resistant material, a bulletproof material, a shielding material, a chemically resistant material, a biohazard resistant material, a radiation resistant material, a moisturizing material, a grounding material, an insulating material, or a combination thereof. For example, one or more protective layers can be one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of polyurethane foam, a layer of graphite, a wire mesh or their combination.

Turning now to FIG. 18, which shows a flow diagram of a method 1800 for manufacturing a core for a fireproof door in accordance with one embodiment of the present invention. At a block 1802, the door core shown in FIG. 1 - 10. In block 1804, a first decorative panel is attached to the upper surface of the door core, and in block 1806, a second decorative panel is attached to the lower surface of the door core. Additional elements may be added as described with reference to FIG. 11-14.

The preferred embodiments of the present invention are described above, however, it will be understood by those skilled in the art that various modifications and changes are possible within the spirit and scope of the invention set forth in the appended claims.

Claims (95)

1. Flame retardant composite product containing: a composite containing gypsum in an amount of 68-90 wt.%, fibers in an amount of 4-26 wt.%, essentially uniformly distributed over the composite, a rheology modifier in an amount of 0.5-6 wt.%; wherein the fibers are a combination of fiberglass, cellulose fiber, polyvinyl alcohol fibers and polypropylene fibers; the composite is cured or allowed to cure to form a cured composite; and the cured composite is a fire-resistant element used in a fire-resistant core of a door, a fire-resistant door or a fire-resistant construction panel, characterized in that the fire-resistant element is selected from a construction panel, door panel, door core, horizontal door trim bar, vertical door trim bar, door lock block door edging or door inserts. 2. The fire-resistant composite product according to claim 1, characterized in that the rheology modifier is methyl hydroxypropyl cellulose (MGPC), methyl hydroxyethyl cellulose (MGEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC). 3. Fire-resistant composite product according to claim 1, characterized in that the composite further comprises a filler in an amount of 10-25 wt.%, Essentially uniformly distributed over the composite. 4. Fire-resistant composite product according to claim 1, characterized in that the composite additionally contains starch in an amount of 2-7 wt.%. 5. Fire-resistant composite product according to claim 1, characterized in that the composite additionally contains vermiculite or clay in an amount of 1-10 wt.%, Essentially uniformly distributed over the composite. 6. Fire-resistant composite product according to claim 1, characterized in that the glass fiber is present in an amount of 1.5-5 wt.%. 7. Fire-resistant composite product according to claim 1, characterized in that fiberglass is present in an amount of 2-10 wt.%; cellulose fiber is present in an amount of 2-8 wt.%; polyvinyl alcohol fibers are present in an amount of 1-4 wt.%; and polypropylene fibers are present in an amount of 0.3-4 wt.%. 8. Fire-resistant composite product according to claim 1, characterized in that the composite does not contain cement or fly ash. 9. Flame retardant composite product containing: a composite containing gypsum in an amount of 60-85 wt.%, fibers in an amount of 1.5-5 wt.%, essentially uniformly distributed over the composite, aggregate in an amount of 10-25 wt.%, essentially uniformly distributed over a composite, starch in an amount of 2-7 wt.% and a rheology modifier in an amount of 0.5-4 wt.%; wherein the fibers are a combination of fiberglass, cellulose fiber, polyvinyl alcohol fibers and polypropylene fibers; the composite is cured or allowed to cure to form a cured composite; and the cured composite is a fire-resistant element used in a fire-resistant core of a door, a fire-resistant door or a fire-resistant construction panel, characterized in that the fire-resistant element is selected from a construction panel, door panel, door core, horizontal door trim bar, vertical door trim bar, door lock block door edging or door inserts. 10. Fire-resistant composite product according to claim 9, characterized in that the composite additionally contains vermiculite or clay in an amount of 1-10 wt.%, Essentially uniformly distributed over the composite. 11. Fire-resistant composite product according to p. 9, characterized in that the fibers have a diameter of 6-25 mm 12. The fire-resistant composite product according to claim 9, characterized in that the rheology modifier is methyl hydroxypropyl cellulose (MGPC), methyl hydroxyethyl cellulose (MGEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC). 13. Fire-resistant composite product according to claim 9, characterized in that the aggregate has an average particle diameter of 1-4 mm 14. The fire-resistant composite product according to claim 9, characterized in that the fire-resistant element has a cross section thickness of 0.125-2 inches (0.32-5.08 cm), a width of 1 inch - 4 feet (2.54 cm - 1.22 m) and a length of 3-10 feet (1.2-3.0 m). 15. Fire-resistant composite product according to claim 9, characterized in that the composite does not contain cement or fly ash. 16. Flame retardant composite product containing: a composite containing gypsum in an amount of 68-90 wt.%, fiberglass in an amount of 2-10 wt.%, essentially uniformly distributed over the composite, cellulose fiber in an amount of 2-8 wt.%, essentially uniformly distributed over a composite, fibers from polyvinyl alcohol in an amount of 1-4 wt.%, essentially uniformly distributed over the composite, polypropylene fibers in an amount of 0.3-4 wt.%, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5-6 wt. %; the composite is cured or allowed to cure to form a cured composite; and the cured composite is a fire-resistant element used in a fire-resistant core of a door, a fire-resistant door or a fire-resistant construction panel, characterized in that the fire-resistant element is selected from a construction panel, door panel, door core, horizontal door trim bar, vertical door trim bar, lock block doors, door borders or door inserts. 17. Fire-resistant composite product according to p. 16, characterized in that the fibers have a diameter of 6-25 mm 18. The fire-resistant composite product according to claim 16, characterized in that the rheology modifier is methyl hydroxypropyl cellulose (MGPC), methyl hydroxyethyl cellulose (MGEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC). 19. The fire-resistant composite product according to claim 16, characterized in that the fire-resistant element has a cross section thickness of 0.125-2 inches (0.32-5.08 cm), a width of 1 inch - 4 feet (2.54 cm - 1.22 m) and a length of 3-10 feet (1.2-3.0 m). 20. Fire-resistant composite product according to p. 16, characterized in that the composite does not contain cement or fly ash. 21. A core for a fireproof door, comprising: a fire-resistant central fabric having a lower surface, upper surface, a first side, a second side, a first end and a second end, wherein the fire-resistant central fabric is made of a first fire-resistant material containing gypsum in an amount of 60-85 wt.%, fiber in an amount of 1, 5-5 wt.%, Essentially uniformly distributed over the composite, aggregate in an amount of 10-25 wt.%, Essentially uniformly distributed over the composite, starch in an amount of 2-7 wt.% And a rheology modifier in an amount of 0.5-4 wt.%; and extruded fire-resistant frame attached to the first side, second side, first end and second end of the fire-resistant central fabric, while the extruded fire-resistant frame is made of a second fire-resistant material containing gypsum in the amount of 70-90 wt.%, fiberglass in the amount of 2-10 wt. .%, essentially uniformly distributed over the composite, cellulosic fiber in an amount of 2-8 wt.%, essentially uniformly distributed over the composite, polyvinyl alcohol fibers in an amount of 1-4 wt.%, essentially uniformly distributed nnye of the composite, polypropylene fibers in an amount of 0.3-4 wt.%, substantially homogeneously distributed throughout the composite, and a rheology modifier in an amount of 0.5-6 wt.%. 22. The core according to p. 21, characterized in that the first flame-retardant material further comprises vermiculite or clay in an amount of 1-10 wt.%, Essentially uniformly distributed over the composite. 23. The core according to claim 21, further comprising: a recess in the first side of the fire-resistant central canvas; and a fireproof lock block located in a recess and attached to a fireproof central web and an extruded fireproof frame, characterized in that the fireproof lock block is made of a second fireproof material. 24. The core according to claim 21, characterized in that the fire-resistant central fabric contains: a first flame retardant fabric made from a first flame retardant material; a second flame retardant fabric made of the first flame retardant material; and an extruded fire-resistant insert located between the first fire-resistant central sheet and the second fire-resistant central fabric and attached to them and passing between the extruded fire-resistant frame on the first side and the second side and attached to it, and the fire-resistant material is made of a second fire-resistant material. 25. The core according to p. 21, characterized in that the extruded fire-resistant frame is made with the possibility of attaching to the fire-resistant central fabric by a set of male-female connectors made in an extruded fire-resistant frame and a fire-resistant central fabric. 26. The core according to p. 25, characterized in that the male-female connectors are triangular, curved, rectangular, angled, sheet pile or a combination thereof. 27. The core according to p. 21, characterized in that the extruded fire-resistant frame contains: first vertical bar; second vertical bar; a first horizontal bar attached to the first vertical bar and the second vertical bar; and a second horizontal bar attached to the first vertical bar and the second vertical bar. 28. The core according to p. 25, characterized in that it further comprises an upper panel attached to the upper surface of the fire-resistant central fabric and an extruded fire-resistant frame, or a lower panel attached to the lower surface of the fire-resistant central fabric, or both panels (upper and lower). 29. The core according to p. 28, wherein the upper panel or lower panel is a lignocellulosic substrate, wood, wood composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic, one or several protective layers or their combination. 30. The core according to p. 28, characterized in that one or more of the protective layers is a flame retardant material, an explosion proof material, a bulletproof material, a shielding material, a chemically resistant material, a biohazard resistant material, a radiation resistant material, a moisturizing material, and grounding material, insulating material, or a combination thereof. 31. The core according to p. 28, characterized in that one or more protective layers are one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, polyurethane foam layer, graphite layer, wire mesh or a combination thereof. 32. The core according to p. 31, characterized in that the fire-resistant central fabric and the extruded fire-resistant frame are covered with intumescent or fire-resistant material. 33. The core according to p. 31, characterized in that the fire-resistant central fabric contains: a central web made of a first flame-retardant material or a second flame-retardant material; an upper insulating panel attached to the upper surface of the central web; and a lower insulation panel attached to the lower surface of the center web. 34. The core according to claim 33, wherein the upper insulating panel and the lower insulating panel are made of corrugated filler having several voids filled with soundproofing material. 35. A fire resistant door comprising: a core comprising (a) a fire-resistant central fabric having a lower surface, an upper surface, a first side, a second side, a first end and a second end, wherein the fire-resistant central fabric is made of a first fire-resistant material containing gypsum in an amount of 60-85 wt.% , fibers in an amount of 1.5-5 wt.%, essentially uniformly distributed over the composite, aggregate in an amount of 10-25 wt.%, essentially uniformly distributed over a composite, starch in an amount of 2-7 wt.% and rheology modifier in the amount of 0.5-4 wt.%, and (b) extruder a bathroom fire-resistant frame attached to the first side, second side, first end and second end of the fire-resistant central fabric, while the extruded fire-resistant frame is made of a second fire-resistant material containing gypsum in the amount of 70-90 wt.%, fiberglass in the amount of 2-10 wt. .%, essentially uniformly distributed over the composite, cellulose fiber in an amount of 2-8 wt.%, essentially uniformly distributed over the composite, polyvinyl alcohol fibers in an amount of 1-4 wt.%, essentially uniformly distributed over composite, polypropylene fibers in an amount of 0.3-4 wt.%, essentially uniformly distributed over the composite, and a rheology modifier in an amount of 0.5-6 wt.%; the first decorative panel attached to the upper surface of the fire-resistant central canvas and extruded fire-resistant frame; and a second decorative panel attached to the lower surface of the fire-resistant central canvas and extruded fire-resistant frame. 36. The fire-resistant door according to claim 35, characterized in that the first fire-resistant material further comprises vermiculite or clay in an amount of 1-10 wt.%, Essentially uniformly distributed over the composite. 37. Fire-resistant door according to claim 35, further comprising: a recess in the first side of the fire-resistant central canvas; and a fireproof lock block located in a recess and attached to a fireproof central web and an extruded fireproof frame, characterized in that the fireproof lock block is made of a second fireproof material. 38. Fire-resistant door according to p. 35, characterized in that the fire-resistant central canvas contains: a first fire-resistant central fabric located between the first side and the second side near the first end, the first fire-resistant central fabric made of a first fire-resistant material; a second fire-resistant central fabric located between the first side and the second side near the second end, the second fire-resistant central fabric made of the first fire-resistant material; and a fire-resistant insert located between the first fire-resistant central fabric and the second fire-resistant central fabric, and attached to them and passing between the extruded fire-resistant frame on the first side and the second side, and attached to it, and the fire-resistant material is made of a second fire-resistant material. 39. Fire-resistant door according to claim 35, characterized in that the extruded fire-resistant frame is made with the possibility of attaching to the fire-resistant central fabric by a set of male-female connectors made in an extruded fire-resistant frame and a fire-resistant central fabric. 40. Fire-resistant door according to claim 35, characterized in that the male-female connectors are triangular, curved, rectangular, angular, sheet pile or a combination thereof. 41. Fire-resistant door according to p. 35, characterized in that the extruded fire-resistant frame contains: first vertical bar; second vertical bar; a first horizontal bar attached to the first vertical bar and the second vertical bar; and a second horizontal bar attached to the first vertical bar and the second vertical bar. 42. The fire-resistant door according to claim 35, characterized in that it further comprises a top panel attached to the upper surface of the fire-resistant central fabric and an extruded fire-resistant frame, or a lower panel attached to the lower surface of the fire-resistant central fabric, or both panels (upper and lower) . 43. The fire-resistant door according to claim 42, wherein the upper panel or lower panel is a lignocellulosic substrate, wood, wood composite, medium-density fiberboard, high-density fiberboard, particleboard, masonite, fiberglass, metal, plastic, one or several protective layers or a combination thereof. 44. The fire-resistant door according to claim 42, characterized in that one or more of the protective layers is a fire-resistant material, an explosion-proof material, a bulletproof material, a shielding material, a chemically resistant material, a biohazard-resistant material, a radiation-resistant material, a moisturizing material, grounding material, insulating material, or a combination thereof. 45. The fire-resistant door according to claim 42, characterized in that one or more of the protective layers are one or more sheets of dry plaster, one or more metal sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets , a layer of polyurethane foam, a layer of graphite, a wire mesh or a combination thereof. 46. Fire-resistant door according to p. 35, characterized in that the fire-resistant central fabric and extruded fire-resistant frame are covered with intumescent or fire-resistant material. 47. Fire-resistant door according to p. 35, characterized in that it further comprises an external strapping attached to each side and end of the extruded fire-resistant frame. 48. Fire-resistant door according to claim 47, characterized in that it further comprises an intumescent strapping material located between the outer strapping and the extruded fire-resistant frame. 49. Fire-resistant door according to claim 35, characterized in that the first decorative panel and the second decorative panel are a lignocellulosic substrate, wood, a wooden composite, medium density fiberboard, high density fiberboard, particleboard, masonite, fiberglass, metal, plastic or a combination thereof. 50. Fire-resistant door according to p. 35, characterized in that the first fire-resistant material and the second fire-resistant material consist of water, gypsum, cellulose or fibrous material, glass, ceramic material and one or more binders. 51. Fire-resistant door according to p. 35, characterized in that the fire-resistant central canvas contains: a central web made of a first flame-retardant material or a second flame-retardant material; an upper insulating panel attached to the upper surface of the central web; and a lower insulation panel attached to the lower surface of the center web. 52. The fire-resistant door according to claim 51, characterized in that the upper insulation panel and the lower insulation panel are made of corrugated filler having several voids filled with soundproofing material.

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