Fire door assembly

Abstract

A door assembly includes a plurality of spacers. The spacers have a first side and a second side. A first sheet of fire-resistant insulating material is coupled to the first side. A second sheet of fire-resistant insulating material is coupled to the second side. A first outer skin is coupled to the first sheet opposite said plurality of spacers. A second outer skin is coupled to the second sheet opposite the plurality of spacers.

What is claimed is:  
     
         1 . A door assembly comprising: 
 a spacer having a first side and a second side;    a first sheet of fire-resistant insulating material coupled to said first side;    a second sheet of fire-resistant insulating material coupled to said second side;    a first outer skin coupled adjacent to said first sheet opposite said spacer; and    a second outer skin coupled adjacent to said second sheet opposite spacer.    
     
     
         2 . A door assembly as recited in  claim 1  wherein said first fire-resistant insulating material and said second fire-resistant insulating material comprises a gypsum-based material.  
     
     
         3 . A door assembly as recited in  claim 1  wherein said gypsum based material has a fibrous mat therearound.  
     
     
         4 . A door assembly as recited in  claim 1  wherein said spacer is selected from the group of wood spacers, gypsum pads, concrete, corrugated cardboard, and a honeycomb material.  
     
     
         5 . A door assembly as recited in  claim 1  wherein said spacer is formed of a plurality of studs.  
     
     
         6 . A door assembly as recited in  claim 5  wherein said plurality of studs are composed of steel.  
     
     
         7 . A door assembly as recited in  claim 1  wherein spacer, said first outer skin and said second outer skin form a void therebetween.  
     
     
         8 . A door assembly as recited in  claim 7  wherein said void has fill material therein.  
     
     
         9 . A door assembly comprising: 
 a first vertical edge;    a second vertical edge space apart from said first vertical edge;    a top rail coupled to said first vertical edge and said second vertical edge;    a bottom rail spaced apart from said top rail coupled to said first vertical edge and said second vertical edge;    a plurality of spaced-apart spacers disposed between said first vertical edge, said second vertical edge, said top rail and said bottom rail, said plurality of spaced-apart spacers having a first side and a second side;    a first sheet of fire-resistant insulating material coupled to said first side;    a second sheet of fire-resistant insulating material coupled to said second side;    a first outer skin coupled to said first sheet opposite said plurality of spacers; and    a second outer skin coupled to said second sheet opposite said plurality of spacers.    
     
     
         10 . A door assembly as recited in  claim 9  wherein said first sheet of fire-resistant insulating material is coupled to said first vertical edge, said second vertical edge, said top rail and said bottom rail.  
     
     
         11 . A door assembly as recited in  claim 9  wherein said first sheet of fire-resistant insulating material is coupled to said first vertical edge, said second vertical edge, said top rail and said bottom rail.  
     
     
         12 . A door assembly as recited in  claim 9  wherein said first fire-resistant insulating material and said second fire-resistant insulating material comprises a gypsum-based material.  
     
     
         13 . A door assembly as recited in  claim 9  wherein said gypsum based material has a fibrous mat therearound.  
     
     
         14 . A door assembly s recited in  claim 9  wherein said plurality of spaced-apart spacers are selected from the group of wood spacers, gypsum pads, concrete, corrugated cardboard, and a honeycomb material.  
     
     
         15 . A door assembly as recited in  claim 9  wherein said plurality of spaced-apart spacers are formed of studs.  
     
     
         16 . A door assembly as recited in  claim 15  wherein said plurality of studs are composed of steel.  
     
     
         17 . A door assembly as recited in  claim 9  wherein said plurality of spaced-apart spacers, said first outer skin and said second outer skin form a void therebetween.  
     
     
         18 . A door assembly as recited in  claim 16  wherein said void has fill material therein.  
     
     
         19 . A door assembly as recited in  claim 9  wherein said first sheet of fire-resistant insulating material, said second sheet of fire-resistant insulating material, and said plurality of spaced-apart spacers comprise a core having a predetermined thickness, said first vertical edge, said second vertical edge, said top rail and said bottom rail having said predetermined thickness.  
     
     
         20 . A method of forming a door comprising: 
 coupling a plurality of spaced-apart spacers between a first sheet of fire-resistant insulating material and a second sheet of fire-resistant insulating material;    coupling a first outer skin to the first sheet of fire-resistant insulating material; and    coupling a second outer skin to the second sheet of fire-resistant insulating material.    
     
     
         21 . A method as recited in  claim 20  wherein coupling forms a void between said plurality of spaced-apart studs, said first sheet of fire-resistant insulating material and said second sheet of fire-resistant insulating material.  
     
     
         22 . A method as recited in  claim 20  further comprising filling said void with a fire-resistant insulating material.  
     
     
         23 . A method as recited in  claim 20  wherein coupling a plurality of spaced-apart spacers comprises coupling a plurality of spaced-apart studs between a first sheet of fire-resistant insulating material and a second sheet of fire-resistant insulating material.  
     
     
         24 . A door assembly comprising: 
 a first vertical edge;    a second vertical edge space apart from said first vertical edge;    a top rail coupled to said first vertical edge and said second vertical edge;    a bottom rail spaced apart from said top rail coupled to said first vertical edge and said second vertical edge;    a plurality of spaced-apart spacers disposed between said first vertical edge, said second vertical edge, said top rail and said bottom rail, said plurality of spaced-apart spacers having a first side and a second side;    a first sheet of fire-resistant insulating material coupled to said first side; and    a second sheet of fire-resistant insulating material coupled to said second side.