CN1662713A - High performance door - Google Patents

Abstract

A high performance (10) door comprising a door shell (14) having a generally planner construction with marginal edges and at least one door skin (18) helping to define an interior door cavity (16) is disclosed. The door member is preferably constructed of a gas-entrained cementitious material and has a compressive strength of at least about 30 Ibf/in<2 >when measured using ASTM C-39. A method for forming a door member for use in construction with the door generally comprising: providing a door shell (14) placing the shell (149 in a fixture, filling the interior door cavity (16) with a gas-entrained cementitious material, green-strength curing the gas-entrained cementitious material, and removing the door shell (14) from the fixture is disclosed. The cured gas-entrained cementitious material provides a gas-entrained cementitious core for use in conjunction with a door.

Description

High performance door

Background of invention

1. invention field

The present invention relates to a kind of high performance door, relate more specifically to a kind of high performance door with gas enclosure bonding door core.

2. background technology

The some occasions that are used for civilian and commercial entrance gate require to have very high performance.For example, meet labeled door, safety door, the high-insulativity door of grade, the weather resistance door that meets the noise reduction sound door of grade and meet grade has been made for many years.The door of typical high-performance gate and other type includes work plane, edge surface, door core material and adhesive.Work plane is as aesthetic layer, at the barrier that is in the light in infrared wavelength and the visible wavelength, barrier, girth member and fire-proof curtain at wind and rain.Edge surface is used as connector between the work plane by using adhesive.In addition, edge surface is as the substrate of door lock and hinge goods.Edge surface can be with the sealing surface of work plane as the weather proof bar.Edge surface also can be used as the substrate connector of girth member, door reinforcement and pairing.The door core material is as the connector between the girth member, work plane, at the delivery member and the fire-proof curtain of the barrier that is in the light in infrared wavelength and the visible wavelength, big block.The member of high-performance gate can have one and be used for multi-purpose member.

The high-performance gate of existing design is much more expensive than traditional door, and/or has limited effect.For example, usually use steel casement door as the labeled door that meets grade.Yet steel casement door can not get rusty when safeguarding, depression, and heat transfer easily in fire resistance test easily.When being filled with polyurethane or expanded polystyrene foam door core, do not connecting on the steel casement door doorframe under the situation of expensive intumescent sealer, steel casement door can't be by 20 or 30 minutes normal pressure fire-protection rating test (ASTM 2074-00 of standard, UL 10C, UBC 7-2-1997 test or British Standard 476 the 22nd part are called BSI 476/22 below).In addition, having feature that client enjoys a lot is that the decoration panel of sharp-pointed embossment can't be pressed in the door skin (skin) of steel casement door usually.

Generally to be combined with the Flame-proof door core heavier usually because of it for wooden labeled door.If do not safeguarded, can break or split in the surface of timber, owing to exist that humidity changes and from the injury of solar ultraviolet, so it is unwell to and is exposed to for a long time under the extraneous weather.And wooden labeled door usually can't be as enough good insulator.

The glass fiber labeled door has been made for has polyurethane foam/gypsum plank door core, mineral door core and phenolic foams.These gate opens often can tolerate gets rusty, caves in, breaks and split, and only needs less maintenance.Yet the glass fiber labeled door generally can't pass through the normal pressure fire resistance test.In addition, the glass fiber labeled door than existing steel labeled door costliness many.

The high-insulativity door has been made for many years.The high-insulativity door can be preserved the energy in the shelter, and saves life in fire, and is all the more so in the time of in the mechanism that is used to physiology individuals with disabilities service.In the design of high-insulativity door, a main consideration is the rigidity of door.In order to strengthen the rigidity of most high-insulativity doors, use the foaming rigid olyurethane usually as the door core material.Even if used the foaming rigid olyurethane usually, be about 2.1 pounds/cubic feet to about 2.4 pounds/cubic feet rigid polyurethane foam for density, it also only has the low young's modulus of elasticity of lower compressive strength (from about 16 ft lbf/square feet to about 20 ft lbf/square feet), about 25000 ft lbf/square inches, and 28 or littler less acoustic propagation coefficient.The prescription that changes polyurethane foam has caused higher cost usually to improve rigidity and sound absorbing capabilities, and this is because must add certain material during making, and is especially true when having used expensive aromatic compound.

Traditional high-insulativity door has certain performance limitations.Most dwelling house is filled with the foam of thermoplasticity or thermosetting organic polymer with the high-insulativity door.These have less than 0.50 than the low-heat loss coefficient.In addition, these doors can't work when placing fire for a long time well.

The current design of high-insulativity door requires to have the firm door skin of metal or glass fiber usually, uses the structural strength that requires usually so that dwelling house to be provided.Firm door skin is generally expensive more than other face attractive in appearance, and therefore, the high-insulativity door that includes firm door skin is generally than other dwelling house Men Genggui.And these doors are lighter than timber.Because the customer can be in the same place bigger weight and better quality usually with security association, so the customer is unwilling to use the high-insulativity door lighter than timber.Require acoustic propagation coefficient surpass 28 occasion, for example near the lightweight commercial buildings the airport, the high-insulativity gate open often provide at acoustic propagation than low-resistance every.

Be desirable to provide a kind of high-performance gate with gas enclosure bonding door core, this Men Xin is easy to make, and can pass through the normal pressure fire resistance test, and anti-ly get rusty, cave in and break, and the only less maintenance of need.It would also be desirable to provide a kind of method that is used to make high-performance gate with above-mentioned feature.

Brief summary of the invention

High-performance gate of the present invention provides an a kind of gas enclosure bonding door core, and its manufacturing cost is lower, can pass through the normal pressure fire resistance test, and anti-ly get rusty, cave in and break, and the only less maintenance of need.Method of the present invention provides a kind of manufacturing to have the means of the high-performance gate of the present invention of above-mentioned feature.

One aspect of the present invention is a high-performance gate, and it comprises the door leaf (door shell) of the general plane structure with edge and at least one skin, and the door skin helps to form an inner chamber and the door member of being located in this inner chamber.This member is made of gas-entrained cementitious material.This member preferably has the compressive strength of at least 30 ft lbf/square inches when using ASTM C-39 to measure.

Another aspect of the present invention be a kind of be used to form can with door structure together the door member method.This method generally includes provides the template with general plane structure, fills this template with gas-entrained cementitious material, this gas-entrained cementitious material is carried out compact strength solidify, and take out this gas-entrained cementitious material from template.The material that is used to construct template is not easy to stick to gas-entrained cementitious material.Cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

Another aspect of the present invention comprise a kind of be used to form can with door use in combination the door member method, comprise the selection gas-entrained cementitious material, gas-entrained cementitious material is cast in the template, allows gas-entrained cementitious material to realize that compact strength solidifies, and from template, take out gas-entrained cementitious material.Gas-entrained cementitious material preferably has the flowability between about 4.825 inches to about 18 inches when using TT flowability method.Cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

The present invention comprises a kind of method that is used to form high-performance gate on the other hand.This method roughly comprises providing to have the door leaf of general plane structure that edge and at least one help to form the door skin of an inner chamber, door leaf is put in the anchor clamps, fill an inner chamber with gas-entrained cementitious material, this gas-entrained cementitious material is carried out compact strength solidify, and from anchor clamps, take out door leaf.Cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

In conjunction with the drawings and read manual, can know these and other purpose of the present invention more.

Brief description

Fig. 1 is the elevation of high-performance gate according to an embodiment of the invention;

Fig. 2 has shown the method that is used to form gas enclosure bonding door core according to an embodiment of the invention;

Fig. 3 has shown the method that is used for stationary housings on the door member according to an embodiment of the invention;

Fig. 4 has shown the aesthetic layer that is applied to according to an embodiment of the invention on the member;

Fig. 5 is the elevation of being constructed the high-performance gate that forms according to an embodiment of the invention by the plastic housing of precolor, the lock box inserts that it has shown the perpendicular stile inserts that is used for fixing two flaps and has been used for engaging with lock box;

Fig. 6 is the elevation of being constructed the high-performance gate that forms according to an embodiment of the invention by the plastic housing of precolor, the lock box inserts that it has shown two groups of inserts that are used for fixing two flaps and has been used for engaging with lock box;

Fig. 7 is the decomposition diagram of one group of inserts being used for according to an embodiment of the invention engaging with flap;

Fig. 8 has shown the method that is used for filling with gas enclosure bonding door core high-performance gate according to an embodiment of the invention; With

Fig. 9 has shown the method that is used for removing from the door inner chamber unnecessary gas-entrained cementitious material according to an embodiment of the invention.

Detailed description of preferred embodiment

Come at length to introduce the present invention below with reference to the accompanying drawings.Referring to Fig. 1, shown door 10 among the figure.According to the preferred embodiment shown in Figure 1, door 10 is radial type access doors.Be appreciated that door 10 refers to radial type garden door without limitation, slidingtype garden door, the radial type inside door, no pressure or normal pressure test grade surpass 90 minutes dwelling house labeled door (house is to the garage), the commercial labeled door of fire resistance rating up to 180 minutes, at the commercial labeled door that is lower than the temperature rise that in 30 minutes, has strict restriction under 450, the safe class door of grade between 20 grades to 40 grades of ASTM F-476, be suitable for satisfying the shock resistance door of high wind speed building regulation, common commercial grade door, the garage door of segmentation and not segmentation and the door that can stop acoustic propagation.According to the preferred embodiment shown in Figure 1, door 10 comprises a member 12 and door leaf 14.Door member 12 preferably is made of gas enclosure bonding door core.The preferred gas-entrained cementitious material that adopts makes up gas enclosure bonding door core.The use of term " gas enclosure " and related notion thereof will at length be discussed hereinafter.Door leaf 14 helps to form door inner chamber 16.For example as U.S. Patent No. 4550540 and No.RE36240 were disclosed, door leaf 14 can be made of glass fiber, and above-mentioned patent is incorporated herein by reference.

As shown in Figure 1, door leaf 14 comprises first skin 18, second skin 20 and doorframe 22.Doorframe 22 comprises the first perpendicular stile 24 and the second perpendicular stile 26.Perpendicular stile 24 and 26 is parallel to each other.Perpendicular stile 24 and 26 is positioned to form vertical relation with first beam 28 and second beam 30.Second beam 30 is parallel to first beam 28 and is spaced from.First beam 28 and second beam 30 extend between perpendicular stile 24 and 26 and they are linked to each other.Be appreciated that after being inserted into door member 12 in the inner chamber 16, first beam 28 can link to each other with 26 with perpendicular stile 24.According to Fig. 1, doorframe 22 has the geometrical construction of rectangle.Yet be appreciated that doorframe 22 can be arranged to multiple geometrical construction, this depends on required application.For example, doorframe can have the dome or the top of arching upward of typical case's " church's formula " building.Door 10 can have the thickness that is between about 0.5 inch to about 3 inches.Door 10 thickness that preferably have between about 1.25 inches to about 1.85 inches.Door 10 can have the height that is between about 48 inches to about 200 inches.Highly be in about 150 inches building door panels that are preferred for building routine to about 200 inches door.Door 10 height that preferably have between about 74 inches to about 96 inches.Door 10 width that have between about 8 inches to about 48 inches.Door 10 width that preferably have between about 10 inches to about 44 inches.Door 10 width that preferably have between about 30 inches to about 42 inches.

As shown in Figure 1, perpendicular stile 24 and 26 and beam 28 and 30 make by pressed laminated wood.Perhaps, can apply sealant on undressed timber, preferably PERMAX 803, so that the restriction current are through timber, this current may make dirty perpendicular stile 24 and 26 and beam 28 and 30, and may change the ratio of water and cementing agent in the gas-entrained cementitious material.Be further appreciated that and adopt no lamination timber to build perpendicular stile 24 and 26 and beam 28 and 30.Be appreciated that in addition perpendicular stile 24 and 26 and beam 28 and 30 can make by hindering any other material that gas-entrained cementitious material moves to outside the edge surface 32.Perpendicular stile 24 and 26 also can be hollow channel member, the metal of pultrusion or extruding reinforced plastics the hollow channel member, make but channel member local or that integrally strengthen by other material beyond the metal with metal, perhaps compress the perpendicular stile of mineral.And, before filling the door inner chamber, a plurality of nails 34 can be inserted in the inward flange of perpendicular stile with gas-entrained cementitious material.Nail 34 is used for doorframe 22 is linked to each other with gas enclosure bonding door core.

As shown in Figure 1, first skin 18 is fixed on first side of doorframe 22, and second skin 20 is fixed on second side of doorframe 22.First skin 18 and second skin 20 preferably by adhesive on doorframe 22.In one embodiment of the invention, door skin 18 and 20 is made of glass fiber, and is fixed on the doorframe 22 by adhesive or fitting face.Yet being appreciated that a skin 18 and 20 can comprise is used for door skin 18 and 20 is fixed to interlocking edge on the doorframe 22.Perhaps, can use the door skin of interlocking to replace first skin 18 and second skin 20.The door skin of interlocking is installed on the doorframe 22, and the edge of interlocking door skin can be clasped by use and be installed together.

As shown in Figure 1, can reinforcing mat 36 be set in doorframe 22 to gain in strength.Reinforcing mat 36 can be fastened on the inward flange of doorframe 22 by using nail 38 or any other securing member.Yet be appreciated that reinforcing mat 36 also can be set in the doorframe 22 without securing member ground, and can be fastened on the interlocking edge or custom-designed anchor clamps of other member beyond the doorframe such as door skin.In this example, gas-entrained cementitious material be arranged on reinforcing mat 36 around, and when solidifying, reinforcing mat 36 is fixed in the inner chamber 16.The material that is used to construct reinforcing mat 36 can vary depending on the application.For example, the material of reinforcing mat can comprise: wire lath, for example wire gauze, grillages frame (grill cloth), aluminum screen, expanded metal or chain link fence; Polymeric web, for example ultra-high molecular weight polyethylene; The building fence; Aramid fiber mat; Fiberglass packing (knitting, woven or non-woven); Carbon fibre mat; Nylon screen; Be coated with the yarn fabric of rubber; And plastic lamination fiber.In addition, can adopt size to be used as the material of reinforcing mat less than solid metal, yarn fabric or the polymer sheet of doorframe 22.Solid material has the size littler than doorframe 18, so gas-entrained cementitious material can not be divided into several sections in cast and setting up period.

Fig. 1 has shown that the first hinge inserts 40, the second hinge inserts 42 and door lock inserts 44 can be inserted in the door leaf 14 before gas-entrained cementitious material being poured in the inner chamber 16.Hinge inserts 40 and 42 can be fastened in the second perpendicular stile 26, adhere in first skin 18 or second skin 20 arbitrary skin or all on the door skin, perhaps be inserted in first skin 18 or second skin 20 arbitrary skin or all in the preform gap in the door skin.Door lock inserts 44 can be fastened in the first perpendicular stile 24, adhere in first skin 18 or second skin 20 arbitrary skin or all on the door skin, perhaps be inserted in first skin 18 or second skin 20 arbitrary skin or all in the preform gap in the door skin.Inserts 40,42 and 44 also can insertion after the cast gas-entrained cementitious material but before it solidifies.First flap 46 and second flap 48 can be fixed on the first hinge inserts 40 and the second hinge inserts 42 by using screw, nail or similar securing member.Door lock assembly 50 can be fixed on the door lock inserts 44 by using screw, nail or similar securing member.

According to situation about using, door member 12 can be by multiple material and by using kinds of processes to make.For example, door member 12 can be formed by gas-entrained cementitious material structure, and this material is controlled low strength cementitious material preferably, and better is controlled low strength cementitious material through the air modification, preferably foam slurry.

Gas-entrained cementitious material refers to the mixture of inorganic material or inorganic material, it is by carrying out chemical reaction to form hydrate and solidify and to strengthen with water, this material can be mingled with the gas that surpasses about 5% volume, preferably be mingled with about 10 to the gas between about 80% volume, better is to be mingled with about 30 to the gas between about 60% volume, preferably is mingled with about 40 to the gas between about 55% volume.Be appreciated that gas can be from multiple source of supply, it includes but not limited to that direct gas injects, contains the microsphere of gas, contains the loose particles of gas, and the state variation of on-the-spot chemical reaction or material.Be further appreciated that the material that is mingled with always is not in gas phase, especially true when the residing variation of ambient temperature of material is remarkable.Be further appreciated that gas can the drift along with the time, and can replace by other gas or liquid.

Controlled low strength cementitious material (CLSM) is a kind of in the gas-entrained cementitious material, refer to the generic term of the binding material that can flow, this material has self-compacting ability and less than the intensity of 1200 ft lbf/square inches (8.27MPa), preferably have the final compressive strength of no lateral confinement of 30-500 ft lbf/square inch, preferably have the unconfined compression strength of 50-250 ft lbf/square inch.CLSM is also referred to as flowable filler, mobile filler usually or has the filler of controlled density.

Controlled low strength cementitious material through the air modification refers to a kind of like this CLSM, wherein be mingled with the air that surpasses 5% volume, preferably be mingled with and have an appointment 10 to the air between about 80% volume, better is to be mingled with to have an appointment 30 to the air between about 60% volume, preferably is mingled with 40 air to about 55% volume of having an appointment.

Foam slurry refers to a kind of controlled low strength cementitious material through the air modification, wherein binding material is any one hydraulic cement, ordinary Portland cement preferably, wherein be mingled with the air or other gas that surpass 5% volume, preferably be mingled with and have an appointment 10 to air or other gas between about 80% volume, better is to be mingled with to have an appointment 30 to air or other gas between about 60% volume, preferably is mingled with and has an appointment 40 to air or other gas between about 55% volume.Ordinary Portland cement is ASTM C-150, and can be the hydraulic cement as the multiple mixing of ASTM C-595 defined.

Foam slurry is preferably used in by foam slurry is injected into and produces gas enclosure bonding door core in the inner chamber 16.Foam slurry prepares by mixing water hydraulic cement, water and blowing agent.As a rule, empty G﹠W mixes with blowing agent, produces the foam solution that has air entrainment.In case foam slurry solidifies, the air that is mingled with peels off with regard to the freeze thawing that has stoped gas enclosure bonding door core.In case after mixing, just foam slurry is transported in the door inner chamber 16.Be used for foam slurry is transported to the method for optimizing discussion at length hereinafter of an inner chamber.Water in the foam slurry is preferably greater than about 38 parts of water than about 100 parts of cement (by weight) with the ratio of cement.If this ratio is less than 0.38, gained door member gets fragility can't accept so.Can add other additive in foam slurry, for example water reducing agent, setting accelerator, super plasticizer, fortifying fibre and expanded polystyrene bead are so that improve such as performances such as flow rate, solidification rate, weight or rigidity.Should be appreciated that fortifying fibre is an aspect ratio greater than 4 fiber or fiber bundle, this makes can strengthen one or multinomial mechanical performance when it exists.

Water reducing agent can improve the workability of cement paste usually, and reduces the amount at the blending water of given workability.As a rule can reduce the water consumption of about 5-15%.Water reducing agent generally is selected from the salt of concentrated naphthalene sulfonic acids, lignin sulfonic acid, salt, carbohydrate and the blend thereof of hydroxycarboxylic acid.Super plasticizer is also referred to as super fluidizing reagent, super water reducing agent and high efficiency water reducing agent, and it is a kind of water reducing agent of about 30% of the consumption of water can being reduced by at least.Though without wishing to be held to arbitrary theory, yet can believe, super plasticizer has deflocculatedly destroyed bigger irregular cement cluster of grains piece by what produce because of absorption and Coulomb repulsion and some steric effect.Super plasticizer generally is selected from sulfonated melamine-formaldehyde condensate, sulfonated naphthalene-formaldehyde condensate, modified lignin sulfonated salts, sulphonic acid ester, polyacrylate, Polystyrene Sulronate and blend thereof.

Be applicable to that a lot of cement of the present invention all contains additive.These additives can comprise close-burning and the additive volcano grey matter.Cementitious additives refers to the mixture of inorganic material or inorganic material, and it can form or help to form binding material, and these materials can be gained in strength to form hydrate by carrying out chemical reaction with water.The caking property additive is rich in silica and alumina.According to ASTM C-539-94, volcano grey matter additive refers to silicic acid material or aluminosilicate material, itself have only very low cementing value or do not have cementing value, yet when being in fine-grained form and having moisture, its can be at normal temperatures and alkalescence and alkaline earth metal hydroxide generation chemical reaction, to form or to help formation to have the compound of adhesive property.The example of volcano grey matter additive comprises coming the C level flying dust of spontaneous combustion brown coal, the F level flying dust that comes the spontaneous combustion soft coal, dusty fuel flying dust, concentrates silica flour, metakaolin, rubber ash and cullet.Additive in the cement is being particularly useful aspect the quality that improves the gained member.

Available insulating gas replaces air entrainment so that better insulating properties to be provided.These gases comprise the molecule of atomic mass greater than air.Possible example comprises halohydrocarbon and hydrohalogenation carbon, for example HCFC-22, HFC-134a, HFC-245fa, HFC-365mfc; Rare gas such as argon gas, xenon and krypton gas; Sulfur hexafluoride; Hydrocarbon, for example pentane; And composition thereof.The technology that insulating gas is incorporated in the foam slurry will be discussed hereinafter.

Door member 12 can not use door leaf 14 and form.Shown in the embodiment among Fig. 2, can cast out has than low slump with than the concrete slab or the cement board that hang down flow rate.The suitable foam slurry that is used for this purpose is included in the foam slurry that has about 4.825 inches to 18 inches flowability when using TT flowability method.TT flowability method comprises the box body that has the end sealing of storage tank from preparation through the southern yellow pine of pressure treatment.Box body is through polyvinylidene chloride, preferably PERMAX 803 handles to be used for seal applications.Box body is preferably at least 26 inches long.Storage tank is preferably 6 inches * 6 inches * 6 inches cube, and has the non-sponginess sliding door that leads to flow channel.This box body is placed on the horizontal plane.The foam slurry of flowability to be tested is injected in the storage tank, and it is wipeed off with 6 inches high marks.Open sliding door, and any foam slurry that will stick on the door scrapes in the storage tank.Foam slurry can flow in the passage.The maximum distance that measurement of species flows out from sliding door after 1.0 minutes.

Be poured into template 64, preferably in the open type template, just can form flat board via nozzle 62 by having than the suitable foam slurry 60 of low slump and low flow rate.Preferably before cast foam slurry 60, the open type template is placed on the horizontal belt 66.The preferred mechanical spreading device 68 dispense foam cement paste in the open type template that uses, and preparation is used for the cured foam cement paste of doorframe.Other appropriate device that is used to distribute and prepare foam slurry comprises sieve (scree) and relief body assembly (embossment unit).In case foam slurry solidifies, just from the open type template, take out the door member of gained.Template can be formed by ultra-high molecular weight polyethylene, high density polyethylene (HDPE), polypropylene, Merlon, polyvinylidene chloride or any material structure that other is difficult for sticking on the foam slurry.Can use the Hardie Plank machine that obtains from Australian James Hardie company to form the continuous placing plate of polymer cement plate.In addition, the continuous placing plate that can use the Cemplank machine that obtains from the Cemplank company of Pennsylvania, America Blandon or Cembord machine to form the polymer cement plate.

The door member that casts out in the open type template can be fixed on the door leaf by adhesive.Should be appreciated that fixing means includes but not limited to utilize securing member, adhesive, is clasped, plastics or metal solder, interlocking and be press-fitted mechanism.

For example, as shown in Figure 3, outer cover 72 can be fixed on the member 74.Outer cover should be understood to the container that finger can hold a core material, wherein this material be provided with the edge maybe can be by forming the edge with provisional external device (ED), and second surface or be connected at least one side at this edge perhaps connects in subsequent process steps.Be to be understood that, outer cover includes but not limited to have lid, many sides panelling of pipe fitting, the pipe fitting that matches with interim outer clamp, sack is folded, turns up or pre-folded and fixed bit and have many sides box body of the upper hem that will fix in subsequent process steps.

As shown in Figure 4, can on door member 80, apply aesthetic layer 78.The aesthetic layer of particular type is decorating film, the dyed layer of transfer printing, the timber that is coated with polyvinylidene chloride and the organic polymer coating that the example of the surface course attractive in appearance of woodiness touch comprises veneer, imitative wood decorations.An example of the decorating film of imitative wood decorations is the thin slices of extruding that contain the dyestuff that can liquefy under different temperatures, as disclosed in U.S. Patent No. 5866054.An example of transfer printing dyed layer is the FINAL FINISH that can obtain from the Immersion Graphics company of Georgia State, USA Columbus.Be appreciated that before applying the surface course attractive in appearance of woodiness touch, can adopt meticulous sandblast or other finishing process to reduce tiny flaw on the component surface.Can in the door member, be molded into wood grain.There is kinds of processes can produce wood grain at present.For example, can from model door skin, construct the mother matrix of silicone rubber or thin polymer film.Also can use following technology in addition: from photoresist, construct the steel mother matrix of acid etching, utilize the nickel chemical vapour deposition (CVD), the engraving that can also use the craft of making or machine to make by wood, metal, pottery or polymer.

And, the decorative glasses fiber tulle of the grain of wood that can obtain from Lance Brown Import-Export company can be molded into the member.Perhaps, wood imitation structure can be the stainless steel foil bag that can obtain from McMaster-Carr company.The stainless steel foil bag suitably is configured as the edge with imitative door.In addition, insertable door member can be machined by CNC, and be coated with external coating, bed material or sealant.

Shown another embodiment of the present invention in Fig. 5, it has the plastics door leaf 84 of precolor.The plastics door leaf 84 preferred methods of blow molding that adopt of precolor are made.Yet be appreciated that also and can use other manufacturing process, this depends on its application.These manufacturing process comprise rotation injection moulding, sheet extrusion, injection mo(u)lding or thermoforming.A kind of especially effectively sheet extrusion method comprises the thin slice that forms biaxial orientation, repairs this biaxial orientation thin slice and makes it have recess, and by using adhesive or supersonic welding to fetch preformed door member is fastened on this biaxial orientation thin slice.A kind of especially effectively injection molding process comprises that injection mo(u)lding goes out the various piece of doorframe, and these parts are tightened together to form doorframe.The example of the plastics of precolor comprises the blend of polystyrene, polyvinyl chloride, PETG, polyolefin, nylon, ABS, ABS-(ABS-glass fiber)-ABS composite material, long fiber thermoplastics, reinforced plastics and these plastics.The preferred ABS that uses.Precolor can obtain uniform surface color, and does not need to paint.

As shown in Figure 5, can place long and narrow inserts 86 along inward flange 88 by hole 90.Long and narrow inserts 86 can reach the height place of precolor plastics door leaf 84 always.First flap 92 and second flap 94 can be fixed on the long and narrow inserts 86 by using screw, nail or similar fasteners.Can door lock assembly 96 be fixed on the door lock inserts 98 by using screw, nail or similar fasteners.

Shown in Fig. 6 and 7,, first group of hollow insert 102 and second group of hollow insert 104 are inserted in the plastics door leaf 84 of precolor the door member being placed an inner chamber or foam slurry after the door inner chamber solidifies.As shown in Figure 7, inserts 102 and 104 is screwed in the member, and fixes by screw thread 78.Can first flap 92 and second flap 94 be fixed on inserts 102 and 104 by using screw, nail or similar fasteners.For only having shown two inserts for simplicity.The quantity and spacing of inserts depends on that inserts will connect the style of flap thereon.

Fig. 8 has shown with foam slurry and has filled an inner chamber and cured foam cement paste to produce the method for optimizing of gas enclosure bonding door core.Be appreciated that and before filling, flexible non-ceramic compound be incorporated in the inner chamber, to strengthen the flexible of gained high-performance gate.According to Fig. 8, one group of door leaf 110 is placed on the platform 112, its orientation makes beam be parallel to ground.First beam preferably includes plug hole 114.Yet being appreciated that door leaf also can be placed with is in any being of value to foam slurry is incorporated into orientation in the inner chamber.These orientation include but not limited to make perpendicular stile to be parallel to ground and to make a skin be parallel to ground.After on being placed on platform 112, clamp this door leaf group 110, and apply about 0.1 ft lbf/square inch to the pressure between about 20 ft lbf/square inches with anchor clamps 116.The about 0.5 ft lbf/square inch of anchor clamps 116 preferred uses is to the pressure between about 2.0 ft lbf/square inches.Be used for suitable anchor clamps of the present invention and comprise platen press, bladder press, pod propulsion forcing press (pod press), lamination line (lamination line) and contained side device.Anchor clamps 116 preferably are made of the platen press with pressing plate 118 and 120.The temperature of pressing plate is in approximately between-2 ℃ to about 95 ℃.The temperature of pressing plate preferably is between about 20 ℃ to about 30 ℃.

Nozzle 122 preferably is inserted in the inner chamber via plug hole 114.Preferably in the beam a plurality of steam vents and groove are being set down, to prevent between the casting cycle of foam slurry, producing too big pressurization.Be further appreciated that between casting cycle, not need the end beam, it can after set up or not be provided with.Nozzle 122 is transported to foam slurry in the inner chamber.Foam slurry can adopt 1 to 5 between the unit increment form and incremental be input in the inner chamber.The preferred increment of 1 to 3 unit that uses is filled into foam slurry in the inner chamber 16.Preferably use the increment of 1 unit to fill an inner chamber 16.

Perhaps, as shown in Figure 9, fill process can comprise that door leaf 128 is placed to a feasible door skin is roughly parallel to ground.Filled the door inner chamber with foam slurry after, available one group of roller 130 runs on a door skin 132, to remove unnecessary gas-entrained cementitious material 134 from the door inner chamber.

If foam slurry includes insulating gas, so preferably carry out following process.With blowing agent premix in the pressure vessel of finding time.Insulating gas is incorporated in this pressure vessel of finding time.Other composition that comprises cement, water, setting accelerator and water reducing agent mixes in colloid blender and ribbon mixer, and these blenders are sealed and find time, with existing of limit air.In case these other compositions mix fully, just introduce the blowing agent/insulating gas mixture of premix in the ribbon mixer of finding time.

The door skin preferably is secured on the wall of anchor clamps by the anchor clamps of finding time.Doorframe preferably has first beam in Strip casting hole.The place is provided with vent plug at plug hole, an inner chamber of finding time again after the marking press anchor clamps of finding time.The door skin is remained on vacuum pressure between the anchor clamps vacuum on the holder wall than high at least about 1 millimetres of mercury of vacuum of door inner chamber.To contain the foam slurry that is mingled with insulating gas then and be pumped into via vent plug in the inner chamber, reduce the pollution of surrounding air cement paste.

The insulating gas that is mingled with or the pore size of air can be subjected to certain influence.During curing, anchor clamps can heat in convection type dielectric oven or micro-wave oven, till the bonding reaction makes cement when having formed constitutionally stable cell-wall (cellwall) around gas that is mingled with and/or the bubble.The time of staying in stove should be enough to realize stable cell-wall, and this depends on the prescription and the furnace temperature of the foam slurry that comprises employed cement and setting accelerator.For air, furnace temperature can be than high about 1 ℃ to about 70 ℃ of environment temperature, and preferred high about 10 ℃ to about 40 ℃, preferably high about 20 ℃ to about 35 ℃.For other gas, this scope can change according to the quality and the molecular weight of insulating gas.

In solidification process, hydration reaction has taken place in foam slurry.This reaction has increased the heat in the door inner chamber.In the group 110 that typically places the fan of 12 in anchor clamps door, the temperature of the foam slurry in the door inner chamber can reach in about 6 hours setting up period than high about 60 ℃ of environment temperature.After having reached constitutionally stable cell-wall, can cool off the excessive pressure that is mingled with gas that comes self-expanding to reduce.In this process, can use traditional heat interchanger to come storage power.

Can on anchor clamps 116, connect pneumatic vibrator 124 and 126,, thereby avoid forming the space because of the bridging of foam slurry so that improvement is mobile and make foam slurry densified. Pneumatic vibrator 124 and 126 also can help to reduce the viscosity of the foam slurry stream that contains thixotropic agent.The US13 pneumatic vibrator that preferred use can obtain from the Global Manufacturing company of U.S.'s Arkansas State Little Rock.This US13 pneumatic vibrator preferably uses one period between about 2 seconds to about 30 seconds.Each incremental add foam slurry during, this US13 pneumatic vibrator preferably uses one period between about 5 seconds to about 10 seconds.

If the door skin constitute by glass fiber and the door skin tensile strength less than about 1.0 * 10 ⁶Ft lbf/square inch so preferably applies vacuum at the external surface to the door skin from anchor clamps 116, so that remain the door skin smooth between casting cycle.Anchor clamps aspirate out the vacuum of about 5psi to about 20psi.The surface of anchor clamps preferably has groove, selects outside the anchor clamps edge with the air that allows to be inhaled in the vacuum ports.

In case the door inner chamber has been filled foam slurry, just capping is fixed on first beam.The door leaf of having filled can be stamped the upper cord of thermoplastic polymer, thermosetting polymer or metal.Perhaps, capping can be formed by open-ended wood structure, and this timber optionally is coated with waterproof coating, preferably the PERMAX 803 that is produced by the Noveon company of Ohio, USA Cleveland.

In case the door inner chamber has been filled foam slurry, and foam slurry is solidified in anchor clamps 116.In case foam slurry can tolerate slump, perhaps tided over the exothermic maximum stage that results from during the hydration reaction, so no matter above-mentioned which phenomenon take place earlier, and foam slurry all will reach condensation point just.After reaching just condensation point, foam slurry will further solidify and reach the final set point, this moment removable door and can not damage a member.Just condensation point and final set point change according to the prescription of foam slurry.The exothermic temperature curve of two kinds of different formulations is provided in following example 3, and it has shown the difference of initial point and final set point.Adopt ASTM method C-403, in the time of can reaching the intensity of about 70 ft lbf/square inches at the foam slurry that penetrometer indicates example 1 door is taken out from anchor clamps.Be further appreciated that these compressive strength different with the compressive strength measured value that obtains by ASTM C-39 (its result will be described below).

Foam slurry can solidify one period between about 1 minute to about 48 hours in anchor clamps, this depends on prescription.Preferably be in the hardening time in anchor clamps between about 5 minutes to about 24 hours.Preferably be in the hardening time in anchor clamps between about 10 minutes to about 24 hours.Cement paste is cured to door can be taken out from anchor clamps and can not causes the process of damage to be called compact strength to solidify.

In order to shorten hardening time, can in foam slurry, add the fast type setting accelerator that coagulates.The fast type setting accelerator that coagulates preferably is injected in the foam slurry stream at the place, end of the nozzle 122 with delivery pipe.Delivery pipe preferably includes flap valve, to reduce the backflow of foam slurry in the delivery pipe.Typical fast type setting accelerator with fixed attention has the alkaline pH value between about 11 to about 13.General sample comprises aluminium base setting accelerator, modification silicate of soda base setting accelerator, liquid base setting accelerator and based on the alkali-free setting accelerator of calcium oxide.These setting accelerator have description in United States Patent (USP) 6221151 and 6025404, these patents are incorporated herein by reference.By using the fast type setting accelerator that coagulates, just can be reduced to hardening time between about 2 minutes to about 10 minutes.

After taking out from anchor clamps, foam slurry can further solidify to reach higher intensity and final set.Can be about 0 day to about 100 days the hardening time after taking out from anchor clamps, is preferably about 3 to about 28 days, preferably about 10 days to about 28 days.The typical range of the compressive strength of the door member that is made of foam slurry that utilizes that ASTM C-39 records is that about 58 ft lbf/square inches are to about 75 ft lbf/square inches.

After generally having introduced the present invention, by the present invention may be better understood with reference to some specific examples, these examples only are provided for illustrative purposes here, and except as otherwise noted, otherwise these examples all do not limit the present invention.

Example 1 and contrast graph A

Can solidify and as the door member preferred foams cement paste of the present invention comprise following:

Composition	Ortho states/dry weight %
		Hydraulic cement	????61.43％
Water	????26.30％
		Foam solution	????9.22％
Water reducing agent	????0.01％
		Setting accelerator	????0.04％
Fortifying fibre	????0.18％
		The expanded polystyrene bead	????2.82％

Table 1

Preferred hydraulic cement is the III type ordinary Portland cement by the Lone-StarIndustries company production of the U.S. Indianapolis of Indiana State.Preferred water is tap water.Foam solution preferably includes 1 part of blowing agent and 40 parts of water.Preferred blowing agent is the liquid masterbatch that concentrates of MEARLCRETE foam that the Cellular Concrete LLC company of N.J. RosellePark produces.Preferred water reducing agent is the RHEOBUILD100 by the MasterBuilders Technologies company production of Ohio, USA Cleveland.The POZZOLITH NC574 that the Master Builders Technologies company that preferred setting accelerator is Ohio, USA Cleveland produces.Preferred fortifying fibre is 3/4ths inches long polypropylene fibres of STEALTH by the Fibermesh Division of Synthetic Industries company production of tennessee,USA Chattanooga.The preferred nominal diameter of expanded polystyrene bead is 1/4 inch, can obtain from the Cellofoam company of Georgia State, USA Conyers.

The method for optimizing of each composition of mix-froth cement paste comprises the steps.In the colloid blender that the Chem Grout company by U.S. Yi Linuosi state LaGrange Park provides, add water, hydraulic cement, setting accelerator and fortifying fibre.These four kinds of compositions preferably add in the colloid blender according to said sequence.In that having been mixed, these compositions afterwards, water reducing agent was joined in the colloid blender at least 45 seconds (mixing fully) to guarantee hydraulic cement and water.By waiting at least 45 seconds, just can greatly improve the effectiveness of water reducing agent to add water reducing agent.After four kinds of compositions of water reducing agent and other are mixed, the content in the colloid blender is sent to preferably in the ribbon mixer that the Chem Grout company by U.S. Yi Linuosi state LaGrange Park provides.In the blowing agent blender, blowing agent, water and air are mixed and form foam solution.Preferably foam solution is added in the ribbon mixer, add the expanded polystyrene bead afterwards.Ribbon mixer preferably is modified into and includes T type beam, to help to mix the content in the ribbon mixer.

The method for optimizing that is used to transmit with the cured foam cement paste comprises the steps.Be in the inner chamber to adopt about 0.5 ft lbf/square inch door leaf to be clipped in the marking press before the filled and process cement paste to the power of about 2.0 ft lbf/square inches.The temperature of pressing plate is in about 20 ℃ and arrives in about 30 ℃ scope.In case the content in the ribbon mixer mixes fully, just preferred use Moino pump is pumped into foam slurry in the inner chamber.The Moino pump does not exceedingly compress the compressed air bubble that is mixed in the foam slurry, in order to avoid destroy the barbotage of foam solution.Foam slurry with the increment of 1 to 5 unit, preferably 1 to 3 unit increment, preferably 1 unit increment and be sent in the door leaf, till the door inner chamber is filled.The door of having filled solidifies in marking press, till foam slurry no longer collapses.Be preferably about 6 hours to about 10 hours the hardening time in the marking press anchor clamps.

Be appreciated that preferably and can carry foam slurry and fill it in the inner chamber by gravity system.In this system, the content in the ribbon mixer is injected in the hopper under action of gravity.Hopper mechanically is positioned on the inner chamber.Foam slurry can flow into the inner chamber from hopper.The advantage of this system is, when contracting the stage through pump pressure by restriction to the destruction of bubble, thereby reduced cost.

Adopt the foam slurry and the replacement of example 1 to come various blowing agents are tested with different blowing agents.Test comprises that it is in the about 4.5 inches cylinder that foam slurry is poured into high about 10 feet and a diameter.The top of cement paste is floating to concordant with the top of cylinder.Best foam will allow foam slurry to avoid shrinking or permanently expand at solidificating period to surpass about 2 millimeters, make concrete column when observing after curing in about 8 hours in fact be higher than the top of cylinder.

Another test is included in 5 gallons the HDPE barrel and makes various blowing agents foaming with air.Preferred " Junior " foam maker that uses the EAB Associates company by Britain Altrincham to provide makes the blowing agent foaming.The tabular load of 85 grams that diameter is about 5.25 inches places the top of foam.If this loads on and still is in foam top after about one hour and as seen, this also can be described as the duration, just so this foam be applicable to manufacturing at least about 8 feet high.

Following table has comprised the test result that is used for various blowing agents:

Blowing agent	Blowing agent type	Cylinder expands	Duration (hour)
				??EABASSOC	Synthesize	Can't obtain	????0.5
??PS?1262	Based on protein	Shrink	????3
				??Mearlcrete	Based on protein	Expand	????＞3
??AFTC101251	Synthesize	Expand	????＞3
				??RHEOCELL?15	Synthesize	Can't obtain	????0.2

Graph A

Should be appreciated that because the duration is too short and can't measure, therefore the cylinder expansion of EABASSOC and RHEOCELL 15 is not measured.

EABASSOC can obtain from the EAB Associates company of Britain Altrincham.The PS1262 blowing agent can obtain from the Master BuildersTechnologies company of Ohio, USA Cleveland.Mearlcrete can obtain from the Cellular Concrete L.L.C. company of N.J. Roselle Park.AFTC101251 can obtain from the Applied Foam Tech Corporation company of Pennsylvania, America Harleysville.RHEOCELL 15 can obtain from Master Builders Tech company.

Synthetic blowing agent is suitable for using with super plasticizer, to improve the flowability of foam slurry.The preferred compositions of blowing agent and super plasticizer is RHEOCELL 30 and RHEOBUILDHRWR 3000 FC.

Example 2

Example 2 is a kind of modification cheaply of foam slurry shown in the example 1.In order to reduce the cost of foam slurry, replace the expanded polystyrene bead with foam solution.The foam slurry of example 2 comprises following:

Composition	Ortho states/dry weight %
		Hydraulic cement	????59.20％
Water	????25.33％
		Foam solution	????15.24％
Water reducing agent	????0.01％
		Setting accelerator	????0.04％
Fortifying fibre	????0.18％

Table 2

Preferred composition is identical with preferred component in the example 1.The preferred hybrid technique that is used for this low cost modification of foam slurry is similar to the hybrid technique of example 1, and difference is not add the expanded polystyrene bead in ribbon mixer.The method for optimizing that is used to transmit with this low cost modification of cured foam cement paste is similar to transmission shown in the example 1 and curing process, and difference is that the preferred consolidation time in the marking press anchor clamps is between about 16 hours to about 24 hours.This example has been passed through ASTM 2074-00 and BSI 476/22 fire resistance test.Contrast chart B has provided the density gradient data in the example 1 and 2.

From the cylinder bottom

Density (pound/cubic inch)

Density (pound/cubic inch)

Height	Example 2	Example 1
			0 foot	????23.24	????24.32
????1	????23.31	????23.58
			????2	????22.55	????24.35
????3	????22.80	????24.73
			????4	????22.67	????24.03
????5	????22.69	????24.16
			????6	????22.83	????23.13
????7	????22.30	????22.65
			????8	????21.73	????22.29
????9	????21.32	????21.66

Chart B

Example 3 and contrast chart C

Preferred foams cement paste of the present invention comprises the hydraulic cement of I type ordinary Portland cement.I type ordinary Portland cement is a kind of low-cost alternative of III type ordinary Portland cement, and this is because I type ordinary Portland cement is not so good as the such particulate of III type ordinary Portland cement.The preferred water mud of example 3 comprises:

Composition	Ortho states/dry weight %
		Hydraulic cement	????62.04％
Water	????26.88％
		Foam solution	????7.99％
Water reducing agent	????0.02％
		Setting accelerator	????0.04％
Polypropylene fibre	????0.18％
		The expanded polystyrene bead	????2.85％

Table 3

Preferred composition is identical with preferred component in the example 1, and difference is that the preferred water hydraulic cement is the I type ordinary Portland cement by the Lone-Star Industries company production of the U.S. Indianapolis of Indiana State.The preferred hybrid technique that is used for the foam slurry of example 3 is similar to the hybrid technique of example 1.The method for optimizing that is used to transmit and solidifies the foam slurry of example 3 is similar to transmission shown in the example 1 and curing process, and difference is that the preferred consolidation time in the marking press anchor clamps is between about 16 hours to about 24 hours.Be appreciated that this curing process can quicken by solidification temperature is brought up on the environment temperature.Under high about 30 solidification temperature than environment temperature, can reduce by 50% hardening time.

III type ordinary Portland cement is than the I type ordinary Portland cement cement of particulate more.As a result, adopt the foam slurry of III type ordinary Portland cement to arrive its final set point in Zao general two hours than the foam slurry that adopts I type ordinary Portland cement.The exothermic temperature curve of these two kinds of foam slurries has confirmed these results:

Time (minute)	Example 1 (adopting III type ordinary Portland cement) (°F)	Example 3 (adopting I type ordinary Portland cement) (°F)
			????0	????67.6	????65
????30	????69.4	????68
			????60	????70.7	????70.2
????90	????72.3	????72.6
			????120	????74.1	(74.6 initial set)
????150	(76.6 initial set)	????78.2
			????180	????79.8	????82.2
????210	????84	????87.4
			????240	????89.6	????94.8
????270	????98.6	(103.2 final set)
			????300	????110.8	????112.8
????330	????117.3	????117.6
			????360	????118.3	????119.6
????390	(119.3 final set)	????120.2
			????420	????118.9	????119.6
????450	????117.3	????118.6

Chart C

Example 4

Can solidify and comprise following as door member and the preferred foams cement paste of the present invention that especially can be used as labeled door:

Composition	Ortho states/dry weight %
		Hydraulic cement	????65.59％
Water	????28.67％

Foam solution	????3.95％
		Water reducing agent	????0.01％
Setting accelerator	????0.04％
		Polypropylene fibre	????0.33％
The expanded polystyrene bead	????1.42％

Table 4

Preferred composition is identical with preferred component in the example 3, difference is, preferred blowing agent is that the Master Builders Technologies company from Ohio, USA Cleveland obtains RHEOCELL 15, and preferred water reducing agent is the RHEOBUILDHRWR3000 FC that the Master Builders Technologies company from Ohio, USA Cleveland obtains.The preferred hybrid technique that is used for foam slurry shown in the example 4 is similar to the hybrid technique of example 1.Transmission is similar with curing process to the transmission in the example 1 with the method for optimizing that solidifies the foam slurry shown in the example 4, and difference is that the preferred consolidation time in the marking press anchor clamps is between about 16 hours to about 24 hours.

Adopt the labeled door of foam slurry shown in the example 4 to pass through 20 minutes ASTM2074-00 normal pressure fire resistance test and 30 minutes BSI 476/22 normal pressure fire resistance test.

Example 5

Can solidify and comprise following as door member and the preferred foams cement paste of the present invention that has than low slump and low flow rate:

Composition	Ortho states/dry weight %
		Hydraulic cement	????61.43％
Water	????26.30％
		Foam solution	????9.22％
Water reducing agent	????0.01％
		Setting accelerator	????0.04％
Polypropylene fibre	????0.18％
		The expanded polystyrene bead	????2.82％

Table 5

Preferred composition is identical with preferred component in the example 1.The preferred hybrid technique that is used for foam slurry shown in the example 5 is similar to the hybrid technique of example 1.

Foam slurry is applicable to and is casting out flat board on the horizontal belt continuously in the open type template, uses at least about 6 feet hydrostatic head pressure and carries.Preferred mechanical spreading device, sieve or the relief body assembly of using comes dispense foam cement paste in template, and preparation is used for the cured foam cement paste of doorframe.The preferred consolidation time in the open type template is between about 8 hours to about 16 hours.

Example 6

A kind of preferred high-performance gate of the present invention is configured to and can stops the heat transmission to pass a member during fire.Adopt ASTM E-152 standard to test, can after 30 minutes on fire, will not be exposed to the surperficial temperature limitation of door in the fire at 250 ℃ according to this preferred high-performance gate of this example.Door leaf is made by SAE 1010 carbon steel or materials similar.

The door member is made of the foam slurry that solidifies.This foam slurry comprises:

Composition	Ortho states/dry weight %
		Hydraulic cement	????65.14％
Water	????24.43％
		Foam solution	????10.07％
Water reducing agent	????＜0.01％
		Setting accelerator	????0.02％
Polypropylene fibre	????0.33％

Table 6

Preferred composition is identical with preferred component in the example 3.The preferred hybrid technique that is used for foam slurry shown in the example 6 is similar to the hybrid technique of example 2.

Foam slurry is sent to size to be similar in the template of door leaf.Template is preferably made by superhigh molecular weight polyethylene material.Template can have embossed pattern, so that be complementary with pattern on the door leaf.With foam slurry with the increment of 1 to 5 unit, preferably 1 to 3 unit increment, preferably 1 unit increment and be sent in the template, till template is filled.

Foam slurry has solidified about 10 days to about 28 days in template after, from template, take out the foamed cement door core or the door member that solidify.On the door member, apply the adhesive that is enough to the door member is fixed on steel door leaf inside.In addition, on door, apply enough adhesives, so that it can pass through the desired bump durability tests of pertinent regulations (ANSI/ISDI105).Typical test request door can stand 1000000 bump circulations, and adhesive should be coated on 70% the surface area of insulated door chipware at least.Adhesive is the elasticity latex adhesive preferably, for example the PPG TRIMBOND T7850 that can obtain from PPG Industries company.Other adhesive comprises that heat melts polyurethane, epoxy resin and structure silicon joint sealing material.

Example 7

A kind of method for optimizing of production high-performance gate of the present invention comprises and being transported in the inner chamber so that shorten hardening time significantly coagulating the type setting accelerator soon.If with coagulating the setting accelerator that the type setting accelerator replaces example 1-6 soon, the foam slurry of example 1-6 also can be used in the fast method with fixed attention of example 7 so.The preferred fast jetcrete of type setting accelerator for obtaining from a plurality of suppliers that coagulate, it is also referred to as gunite.

The fast preferred hybrid technique that coagulates method is similar to the hybrid technique of example 1-6, and difference is, does not add setting accelerator in the colloid blender.

The method for optimizing of transmission and cured foam cement paste comprises the steps.In case the content in the ribbon mixer mixes fully, just preferred use Moino pump is pumped into foam slurry in an inner chamber or the open type template.The Moino pump does not exceedingly compress the compressed air bubble that is mixed in the foam slurry, in order to avoid destroy the barbotage of foam solution.The fast type setting accelerator that coagulates preferably is injected in the foam slurry when the Moino pump is left at the nozzle head place at cement paste.The preferred delivery pipe that uses injects the fast type setting accelerator that coagulates.Be back in the delivery pipe for fear of foam slurry, the end of delivery pipe preferably includes flap valve.Setting time is preferably about 2 minutes to about 10 minutes.

Comparative examples 8

In the prescription of the foam slurry that contains the expanded polystyrene bead, the foam solution that should add optimised quantity is to reduce being mixed in the destruction of the foam bubble in the foam slurry.Following table discloses the expanded polystyrene bead that the contains 37 parts of volumes foam slurry than the foam solution of 63 parts of volumes:

Composition

Ortho states/dry weight %

Hydraulic cement	????61.43％
		Water	????26.29％
Foam solution	????9.22％
		Water reducing agent	????0.01％
Setting accelerator	????0.04％
		Polypropylene fibre	????0.18％
The expanded polystyrene bead	????2.82％

Table 7

If adopt the prescription shown in the table 7, can add so with respect to the volume of expanded polystyrene bead is the extra foam solution of 22.8 parts of volumes, to reach the optium concentration of foam solution.

Following table discloses the expanded polystyrene bead that the contains 18 parts of volumes foam slurry than the foam solution of 82 parts of volumes:

Composition	Ortho states/dry weight %
		Hydraulic cement	????61.02％
Water	????26.12％
		Foam solution	????11.26％
Water reducing agent	????0.01％
		Setting accelerator	????0.04％
Polypropylene fibre	????0.18％
		The expanded polystyrene bead	????1.37％

Table 8

If adopt the prescription shown in the table 8, can add so with respect to the volume of expanded polystyrene bead is the extra foam solution of 14 parts of volumes, to reach the optium concentration of foam solution.

Though shown and introduced embodiments of the invention, be not mean that these embodiment show and introduced institute of the present invention might form.On the contrary, the used term of this manual is descriptive and nonrestrictive term, is appreciated that under the premise without departing from the spirit and scope of the present invention, can carry out multiple variation.

Claims (39)

1. one kind high performance, comprising:

Have edge and at least one and help to form the door leaf of general plane structure of the door skin of an inner chamber; With

Be located at the door member in the described door inner chamber, described door member is made of gas-entrained cementitious material.

2. high-performance gate according to claim 1 is characterized in that, described door member has the compressive strength at least about 30 ft lbf/square inches when adopting ASTM C-39 to measure.

3. high-performance gate according to claim 1 is characterized in that, described door member has greater than about 2.6 pounds/cubic inch density.

4. high-performance gate according to claim 1 is characterized in that, described door leaf comprises doorframe and first skin and second skin.

5. high-performance gate according to claim 1 is characterized in that described door leaf is made of the plastics of precolor.

6. high-performance gate according to claim 1 is characterized in that, for the fire-protection rating tests in 20 minutes of adopting ASTM2074-00, UL 10C or UBC 7-2-1997 testing standard, described high-performance gate is fire-resistant.

7. high-performance gate according to claim 1 is characterized in that, for the fire-protection rating tests in 30 minutes of adopting the BSI476/22 testing standard, described high-performance gate is fire-resistant.

8. high-performance gate according to claim 1 is characterized in that, described high-performance gate has 20 level security grades according to ASTM F-476.

9. high-performance gate according to claim 1 is characterized in that described door leaf comprises outer cover, and described outer cover is positioned on the described door member and with fastening devices to be fixed.

10. high-performance gate according to claim 1 is characterized in that described door leaf is made of metal, and adopts adhesive on described door member.

11. high-performance gate according to claim 1 is characterized in that, described door member is the cured article of foam slurry.

12. high-performance gate according to claim 11 is characterized in that, described foam slurry contains hydraulic cement and water.

13. high-performance gate according to claim 12 is characterized in that, described foam slurry also contains blowing agent.

14. high-performance gate according to claim 13 is characterized in that, described foam slurry also contains at least a composition that is selected from water reducing agent, setting accelerator and the fortifying fibre.

15. high-performance gate according to claim 12 is characterized in that, described hydraulic cement contains volcano grey matter additive.

16. high-performance gate according to claim 12 is characterized in that, described hydraulic cement contains cementitious additives.

17. high-performance gate according to claim 15 is characterized in that, described volcano grey matter additive is selected from C level flying dust, F level flying dust, dusty fuel flying dust, concentrates silica flour, metakaolin, rubber ash and cullet.

18. high-performance gate according to claim 1 is characterized in that, described door leaf comprises the aesthetic layer that is applied on the described door member.

19. high-performance gate according to claim 18 is characterized in that, described aesthetic layer comprises imitative wooden aesthetic layer.

20. high-performance gate according to claim 18 is characterized in that, described aesthetic layer comprises surface course attractive in appearance.

21. high-performance gate according to claim 18 is characterized in that, described aesthetic layer comprises the aesthetic layer of precolor.

22. high-performance gate according to claim 18 is characterized in that, described aesthetic layer is selected from the dyed layer of veneer, decorating film, transfer printing, the timber that is coated with polyvinylidene chloride and organic polymer coating.

23. one kind be used to form can with door use in combination the door member method, described method comprises:

Template with general plane structure is provided, and the material that wherein is used to construct described template is not easy to stick to gas-entrained cementitious material;

Fill described template with described gas-entrained cementitious material;

Described gas-entrained cementitious material is carried out compact strength solidifies; With

Take out the described gas-entrained cementitious material of solidifying from described template, wherein said cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

24. method according to claim 23 is characterized in that, described gas-entrained cementitious material contains foam slurry.

25. method according to claim 23 is characterized in that, the described material that is used to construct described template is selected from ultra-high molecular weight polyethylene, high density polyethylene (HDPE), polypropylene, Merlon and polyvinylidene chloride.

26. one kind be used to form can with door use in combination the door member method, described method comprises:

Select gas-entrained cementitious material, described material has the flowability between about 4.825 inches to about 18 inches when adopting the test of TT flowability method;

Described gas-entrained cementitious material is cast in the template;

Make described gas-entrained cementitious material realize that compact strength solidifies; With

Take out described gas-entrained cementitious material from described template, wherein said cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

27. a method that is used to form high performance door, described method comprises:

Provide and have the door leaf of general plane structure that belt edge and at least one help to form the door skin of an inner chamber;

Described door leaf is put in the anchor clamps;

Fill described door inner chamber with gas-entrained cementitious material;

Described gas-entrained cementitious material is carried out compact strength solidifies; With

Take out described door leaf from described anchor clamps, wherein said cured gas-entrained cementitious material provides the door core that can bond with the gas enclosure that door uses in combination.

28. method according to claim 27 is characterized in that, described method is inserted into flexible non-ceramic compound in the described door inner chamber before also being included in and filling described door inner chamber.

29. method according to claim 27 is characterized in that, described anchor clamps are made of marking press.

30. method according to claim 27 is characterized in that, described door leaf is put in the described anchor clamps comprise the steps:

Described door leaf is placed to makes described at least one skin be roughly parallel to ground; With

At least one roller is rolled on a described door skin therein, unnecessary gas-entrained cementitious material is removed away from described door inner chamber.

31. method according to claim 27 is characterized in that, described method also comprises with pneumatic vibrator stirs described gas-entrained cementitious material, to prevent forming the space in described gas-entrained cementitious material.

32. method according to claim 27 is characterized in that, described door leaf comprises: first skin, and it has first external surface and the first relative inner surface outside being exposed to; Second skin, it has second external surface and the second relative inner surface outside being exposed to; And doorframe, described doorframe is connected on described relative first inner surface and relative second inner surface.

33. method according to claim 32 is characterized in that, described doorframe comprises perpendicular stile and beam, and described perpendicular stile is made of pressed laminated wood, and described beam is made of high density polyethylene (HDPE)-wood fiber, and wherein said first skin and second skin contain glass fiber.

34. method according to claim 33 is characterized in that, described method also is included in before the gas-entrained cementitious material filling door inner chamber, a plurality of nails is inserted at least one inward flange of described perpendicular stile; Wherein said a plurality of nail is used for described doorframe is linked to each other with described gas enclosure bonding door core.

35. method according to claim 32 is characterized in that, described method also comprises reinforcing mat is fastened at least one inward flange of described doorframe.

36. method according to claim 35 is characterized in that, described reinforcing mat comprises the wire lath sheet.

37. method according to claim 36 is characterized in that, described wire lath sheet chosen from Fe silk screen, grillages frame, aluminum screen, chain link fence and expanded metal.

38. method according to claim 35 is characterized in that, described reinforcing mat comprises the polymeric web sheet.

39., it is characterized in that described polymeric web sheet is selected from polythene net, aramid fiber mat, carbon fibre mat, nylon screen, the fabric that is coated with rubber and plastic lamination fiber mat according to the described method of claim 38.

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