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HIGH OPERATING DOOR BACKGROUND OF THE INVENTION. 1. Field of the Invention The present invention is directed to a high performance door, and more specifically, a high performance door having a cement core entrapped with gas. 2. Background of the Branch Various applications for residential and commercial entrance doors require high levels of operation. For example, fire classified doors, security doors, high isolation doors, classified sound reduction doors, and weather resistant doors have been manufactured for many years. The typical high performance door, as well as other types of doors, include face surfaces, edge surfaces, core materials, and adhesives. Face surfaces function as an aesthetic layer, a barrier to light at infrared and visible wavelengths, a barrier to rain and wind, a reinforcing member, and a barrier to fire. The edge surfaces, through the use of adhesives, act as a connecting element between the face surfaces. In addition, the edge surfaces act as a substrate to hold and articulate equipment. In conjunction with the face surfaces, the edge surfaces act as a sealing surface for weathering. The edge surfaces also serve as a stiffening member, a door reinforcement and a matching substrate connector. The core material serves as a reinforcing member, a connecting element between face surfaces, a barrier to light at infrared and visible wavelengths, and mass mass provider, and a fire barrier. The elements of the high-functioning door can have an element that serves multiple purposes. The current designs of high performance doors are substantially more expensive than conventional doors and / or have limited efficiency. For example, steel doors are frequently used as doors classified for fire. However, steel doors rust when they are not maintained, easily indented, and transmit heat easily during fire tests. When filled with polyurethane or expanded polystyrene foam cores, steel doors can not pass conventional 20 or 30 minute positive pressure fire rating tests (ASTM 2072-00, UL 10C, UBC 7-2-1997 or British Standard 476, Section 22, hereinafter referred to as BSI 476/22) without attaching expensive intumescent seals to the steel door frame. In addition, decorative panels with sharp engravings, a feature highly desired by customers, can not be stamped typically on steel door skins. Wood fire doors without typically heavy since they typically incorporate a fire retardant core. The wooden door faces will split or crack if they are not maintained, and are generally unsuitable for exposure to the weather for prolonged periods due to moisture variations and damage of the sun's ultraviolet rays. In addition, fire way doors typically do not act as sufficient thermal insulators. The fiberglass fire doors have been made with polyurethane foam / gypsum board cores, mineral cores and phenolic foam. These doors are typically resistant to rust, indentation, cracking, and splitting and require relatively low maintenance. However, fiberglass fire doors regularly fail positive pressure fire tests. In addition, fiberglass fire doors are substantially more expensive than existing steel fire doors. The high insulation doors have been manufactured for many years. The high insulation doors conserve energy in residences and save lives during fires, especially in institutions that serve physically disabled people. When designing high insulation doors, one of the main considerations is the stiffness of the door. To improve stiffness in many high-insulation doors, rigid foamed polyurethane is commonly used as a core material. Even though rigid foamed polyurethane is typically used, it suffers from relatively low compressive strength (from about 16 lbf / ft2 to about 20 lbf / ftz), a relatively low Young's modulus of about 25,000 lkb / in2, and a coefficient of relatively low sound transmission of 28 or less for rigid polyurethane foams with densities of about 2.1 lg / ft3 to about 2.4 lb / ft3. Changing the formulation of polyurethane foams to improve rigidity and sound protection typically results in higher costs due to added materials needed for manufacturing, especially the use of expensive aromatic ring compounds. Conventional elevated insulation doors suffer from certain operating limitations. Most of the high insulation doors used in residences are filled with thermoplastic foams or thermosetting organic polymers. These doors have a relatively low bill of less than 0.50. Also, these doors do not work well during prolonged exposure to fire. Current designs of high-insulated doors generally require rigid metal or fiberglass skins to provide the structural strength that is typically necessary for residential applications. Rigid skins are generally more expensive than other aesthetic surfaces, therefore, high insulation doors composed of rigid skins typically cost more than other residential doors. In addition, these doors are lighter in weight than wooden doors. Since consumers correlate increased weight with increased quality and safety, consumers are not attracted to high-insulated doors that are lighter than wooden doors. Highly insulated doors commonly provide insufficient resistance to sound transmission for use in areas that require sound transmission coefficients that exceed approximately 28, for example, in light commercial buildings near airports. It would be desirable to provide a high operating door with a gas-entrained cement core that is relatively inexpensive to manufacture, passes positive pressure fire tests, resists rust, indentation and cracking, and requires relatively low maintenance. It would also be desirable to provide a method for manufacturing a high performance door with the above mentioned attributes. COMPENDIUM OF THE INVENTION The high performance doors of the present invention provide a gas-entrained cement core that is relatively inexpensive to manufacture, passes positive pressure fire tests, resists rust, indentation, and cracking, and requires relatively low maintenance. The methods of the present invention provide a means for manufacturing the high performance doors of the present invention with the above mentioned attributes. One aspect of the present invention is a raised operating door comprising a door shell having a generally flat construction with marginal edges and at least one door skin which helps define an interior door cavity and a door member disposed within of the interior door cavity. The door member is constructed of a gas-entrained cementitious material. Preferably, the door member has a compressive strength of at least 30 lbf / in2 when measured using ASTM C-39. Another aspect of the present invention is a method for forming a door member for use in construction with a door. The method generally comprises providing a shape having a generally flat construction, filling the shape with a gas-entrained cementitious material, greening the gas-entrained cementitious material, and removing the cured gas-trapped cementitious material from the form. The material used to build the shape does not easily adhere to the gas-entrained cementitious material. The cementitious material trapped in cured gas provides a trapped cement core. in gas for use in conjunction with the door. Yet another aspect of the present invention includes a method for forming a door member for use in conjunction with a door comprising selecting a gas-entrained cementitious material, molding the gas-entrained cementitious material into a shape, allowing the entrained cementitious material in gas reach cured green resistance, and separate the cementitious material trapped in gas of the form. The gas entrained cementitious material preferably has a fluidity of between about 12.26 cm (4,825 inches) and about 45.72 cm (18 inches) when tested using the flow method TT. The cementitious material trapped in cured gas provides a gas-entrained cement core for use in conjunction with the door. Another aspect of the present invention includes a method for forming a high operating door. The method is generally comprised of providing a door shell that has a generally flat construction with marginal edges and at least one door skin that helps define an interior door cavity, place the door shell in an accessory, fill the interior of door cavity with a cementitious material trapped in gas, cure in green resistance the cementitious material trapped in gas, and remove the door shell of the accessory. The cementitious material trapped in cured gas provides a gas-entrained cement core for use in conjunction with the door. These and other objects of the present invention will become more apparent from a reading of the specification in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front elevational view of a high operating door in accordance with one embodiment of the present invention; Figure 2 illustrates a method for forming a gas-entrained cement core in accordance with one embodiment of the present invention; Figure 3 illustrates a method for securing a housing on a door member in accordance with one embodiment of the present invention; Figure 4 illustrates an aesthetic layer applied to a door member in accordance with an embodiment of the present invention; Figure 5 is a front elevational view of a raised working door constructed with a pre-pigmented plastic shell showing a vertical strut insert to secure two articulation plates and a clamping box insert for attaching a clamping box in compliance with one embodiment of the present invention; Figure 6 is a front elevational view of the high-functioning door constructed with a pre-pigmented plastic shell showing two sets of inserts for securing two hinge plates and the insertion of fastening box for attaching the clamping box in accordance with one embodiment of the present invention; Figure 7 is a detailed view of a set of inserts for coupling a hinge plate in accordance with an embodiment of the present invention; Figure 8 illustrates a method for filling high operating doors with a gas-entrained cement core in accordance with one embodiment of the present invention; and Figure 9 illustrates a method for removing excess gas entrained cementitious material from an interior door cavity in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED MODALITIES The present invention will now be described in detail with reference made to the accompanying drawings.
Referring to Figure 1, the door 10 is illustrated. In accordance with the preferred embodiment illustrated in Figure 1 the door 10 is an articulated entry door. It is understood that the door 10 refers to, but is not limited to, articulated patio doors, sliding patio doors, hinged interior doors, residential fire doors (house to garage) with neutral or positive pressure test ratings up to 90 minutes, commercial fire doors with ratings up to 180 minutes, commercial fire doors with restricted temperature rise in 30 minutes of less than 232 ° C (450 ° F), security classified doors with ratings between 20 and 40 degrees compliance with ASTM F-476, impact-resistant doors suitable for filling high wind speed construction codes, general commercial grade doors, segmented and non-segmented garage doors and doors resistant to sound transmission. In accordance with the preferred embodiment illustrated in Figure 1, the door 10 includes a door member 12 and a door shell 14. The door member 12 is preferably comprised of a gas-entrained cement core. A gas-entrained cementitious material is preferably used to build the gas-entrained cement core. The terms caught in gas, as used in relationship concepts, are discussed in more detail below. The door shell 14 helps to define the interior door cavity 16. The door shell 14 may be comprised of fiberglass, for example, as described and incorporated by reference in US Patents. Nos. 4,550,540 and RE 36,240. As shown in Figure 1, the door shell 14 includes first door skin 18, second door skin 20, and door frame 22. The door frame 22 includes a first vertical post 24 and a second vertical post 26. The vertical posts 24 and 26 are parallel to each other. The uprights 24 and 26 are positioned in a relationship perpendicular to the first rail 28 and second rail 30. The second rail 30 is parallel to and separated from the first rail 28. The first rail 28 and the second rail 30 extend between and connect to the vertical stiles 24 and 26. It is understood that the first rail 28 can be connected to the uprights 24 and 26 after the door member 12 is inserted into the interior door cavity 16. In accordance with Figure 1, the door frame 22 has a rectangular geometric configuration. However, it is understood that the door frame 22 can be arranged in a variety of geometric configurations depending on the desired application. For example, the door frame may have a rounded top or "mission style" architecture arch. The door 10 can have a thickness of between about 12.7 mm. (0.5 inches) and approximately 7.62 cm (3 inches). Preferably, the door 10 has a thickness between about 3.18 cm (1.25 inches) and about 4.70 cm (1.85 inches). The door 10 can have a height of between approximately 121.92 cm (48 inches) and approximately 508 cm (200 inches). Door heights of approximately 381 cm (150 inches) to approximately 508 cm (200 inches) are preferred for construction of special architectural door panels. Preferably, the door 10 has a height between about 187.96 cm (74 inches) and about 43.84 cm (96 inches). The door 10 can have a width between about 20.32 cm (8 inches) and about 121.92 cm (48 inches). Preferably, the door 10 has a width of between about 25.4 cm (10 inches) and about 111.76 cm (44 inches). More preferably, the door 10 has a width of between about 76.20 cm (30 inches) and about 106.68 cm (42 inches). As shown in Figure 1, the uprights 24 and 26 and the rails 28 and 30 are made of laminated wood. Alternatively, the untreated wood can be coated with a sealant, preferably PERMAX 803, to restrict the flow of water through the wood that could possibly stain the uprights 24 and 26 and rails 28 and 30 and could possibly change the ratio of water to cement in the cementitious material trapped in gas. It is also understood that the non-laminated wood can be used to construct the vertical uprights 24 and 26 and rails 28 and 30. Furthermore, it is understood that the vertical uprights 24 and 26 and the rails 28 and 30 can be made from any other material capable of blocking the migration of the gas-entrained cementitious material away from the edge faces 32. The uprights 24 and 26 can also be a hollow channel of extruded reinforced plastic, a hollow metal channel, or channel partially or totally reinforced with metal of a material other than metal, or a compressed mineral vertical upright. Additionally, a plurality of nails 34 can be inserted towards the inner edges of the vertical uprights before filling the interior door cavity with the gas-entrained cementitious material. The nails 34 serve to connect the door frame 22 to the gas-entrained cement core. As illustrated in Figure 1, the first door skin 18 is secured to a first side of the door march 22 and a second door skin 20 is secured to a second side of the door frame 22. Preferably, the first door skin 18 and the second door skin 20 are secured to the door frame 22 with adhesive. In one embodiment of the present invention, the door skins 18 and 20 are constructed of fiberglass and can be secured to the door frame 22 with adhesive or mating surfaces. However, it is understood that the door skins 18 and 20 may include inter-rake edges that function to secure the door skins 18 and 20 to the frame.
22 of door. Alternatively, an intersubject skin can be used, instead of the first door skin 18 and second door skin 20. The intersution door skin fits over the door frame 22 and the edges of the door skin of the interplay coincide together through the use of press fittings. As shown in Figure 1, the reinforcing mat 36 can be placed within the door frame 22 for additional strength. The reinforcing mat 36 can be fastened to the inside edges of the door frame 22 using nails 38 or any other fastening means. However, it is understood that the reinforcing mat 36 may be placed within the door frame 22 without fasteners, and may be fastened to items other than the door frame such as inter-rake edges of the skins or retention fittings designed for the purpose . In this example, the gas-entrained cementitious material is placed around the reinforcing mat 36 and secures the reinforcing mat 36 within the inner door cavity 16 upon curing. The material used to build the reinforcing mat 36 may vary depending on the application. By. example, reinforcing mat materials may include metal mesh, such as chicken wire, grid cloth, aluminum screen, expanded metal, or near link chain; the polymeric mesh, such as ultra high molecular weight polyethylene; close to construction; aramid fiber mat; fiberglass mat (sewn, woven, or non-woven); carbon vibrating mat; nylon sieve; textile coated with rubber; and plastic laminated fibers. In addition, solid metal, textile or polymeric sheets of smaller dimensions than the door frame 22 can be used as reinforcing mat materials. The solid material has smaller dimensions than the door frame 18 so that the gas-entrained cementitious material is not segmented during casting and curing. Figure 1 illustrates that the first hinge insert 40, second hinge insert 42 and fastener insert 44 can be inserted into the door shell 14 before pouring the gas entrained cementitious material into the interior door cavity 16. The hinge inserts 40 and 42 can be secured to the second upright 26, adhere to either or both of the first door skin 18 or second door skin 20, or inserted into previously defined spaces in either or both of the first door skin 18 or both. the second door skin 20. The holding insert 44 can be attached to the first vertical post 24, adhere to either or both of the first skin 18 of door or second door skin 20, or inserted into previously defined spaces in either or both of the first door skin 18 or second door skin 20 The inserts 40, 42 and 44 can also be inserted after the gas-entrained cementitious material has been poured, but before it has been cured. The first articulation plate 46 and second articulation plate 48 can be secured to the first hinge insert 40 and second hinge insert 42 using a screw, nail, or similar fastener. The fastening apparatus 50 can be secured to the fastening insert 44 using a screw, nail or similar fastener. The door member 12 can be made from a variety of materials using a variety of processes depending on the application. For example, the door member 12 can be constructed of the gas entrained cementitious material, preferably a low resistance controlled cementitious material, more preferably an air-controlled controlled low strength cementitious material, and more preferably a cement slurry. foamed Gas-entrained cementitious materials refer to inorganic materials or mixtures of inorganic materials that are set and develop resistance through a chemical reaction with water by formation of hydrates, and that traps more than about 5% by volume of gas, preferably between about 10 and about 80% by volume, more preferably, between about 30 and about 60% by volume, and more preferably between about 40 and about 55% in volume. It is understood that the trapped materials may not always be in the gas phase, particularly when the environmental temperatures at which the article is exposed change significantly. It is further understood that gases can migrate through time and be replaced by other gases or liquids. The low resistance controlled cementitious material (CLSM), a secondary set of gas-entrained cementitious materials, refers to a generic term for fluid cementitious materials that have a self-compacting property and a strength of less than 8.27 MPa (1,200 lbf / in2 ), preferably an unconfined final compressive strength of 30-500 lbf / in2, and more preferably an unconfined compressive strength of 50-250 lbf / in2. CLSMs are also commonly referred to as a fluid fill, flow fill or controlled density fill. Air-controlled controlled low strength cementitious materials are referred to as CLSM having therein trapped more than 5% by volume of air, preferably between about 10 to about 80% by volume, more preferably between about 30 to about . 60% by volume of air, and more preferably around 40 to about 55% by volume of air. Foamed cement suspensions refer to a type of air-controlled, low-resistance, cementitious material in which the cementitious material is any type of hydraulic cement, more preferably Portland cement, in which air or other gases are trapped more than 5% by volume of air or other gas, preferably between about 10 to about 80% by volume of air or others, more preferably between about 30 to about 60% by volume of air or other gas, and more preferable between about 40 to about 55% by volume of air or other gas. Portland cement is defined in ASTM C-150 and is a mixed hydraulic cement variety as defined in ASTM C-595. The most preferably foamed cement suspensions are used to produce gas-entrained cement cores by transferring the foamed cement slurry to the inner door cavity 16. The foamed cement suspension is prepared by mixing hydraulic cement, water, and a foaming agent. Typically, air and water are mixed with the foaming agent to produce a foaming solution with trapped air. Once the foamed cement slurry is cured, trapped air inhibits freeze-thaw flaking of the gas-entrained cementitious core. Once mixed, the foamed cement suspension can be transferred to the interior door cavity 16. Preferred methods for transferring the foamed cement suspension to the inner door cavity are discussed in more detail below. Preferably, the ratio of water to cement in the foamed cement suspension is greater than about 38 parts of water to about 100 parts of cement by weight. If the ratio is below 0.38, the resulting gate member may be unacceptably weak. Additional additives, such as water reducers, setting accelerators, superplasticizers, reinforcing fibers, and expanded polystyrene beads, can be added to the foamed cement slurry to improve properties, such as flow rate, curing rate, weight, or rigidity. It should be understood that reinforcing fibers refer to a fiber or a fiber bundle having a ratio between dimensions greater than 4, which results in one or more increased mechanical properties when present. The water reducers, in general,. improve the working capacity of cement suspensions and reduce the amount of mixing water for a given work capacity. Typically this is about 5-15% reduction in water use. Water reducers are often attracted to the groups consisting of condensed naphthelenesulfonic acids, salts of lignosulfonic acids, salts of hydroxycarboxylic acids, carbohydrates and mixtures thereof. Superplasticizers, also known as super-fluidizers, super water reducers, and high-scale water reducers, are a class of water reducers capable of reducing water use by at least about 30%. While not wishing to be bound by any theory, it is believed that superplasticizers break up the large irregular agglomerates of cement particles in view of deflocculation due to adsorption and electrostatic repulsion, as well as some spherical effects. The superplasticizers are typically drawn from a group consisting of sulfonated melamine-formaldehyde condensates, sulfonated naphthalene-formaldehyde condensates, modified lignosulfonates, sulfonic acid esters, polyacrylates, polystyrene sulfonates, and mixtures thereof.
Many cements that are suitable for use in the present invention contain additives. These additives may include cementitious and pozzolanic additives. Cement additives refer to an inorganic material or mixture of inorganic materials that forms or helps to form cementitious materials that develop resistance by chemical reaction with water by formation of hydrates. Cementitious additives are generally rich in silica and alumina. In accordance with ASTM C-539-94, pozzolanic additives refer to silicious or alumino-silicious materials that have little or no cement value, but when they are in finely divided form and in the presence of moisture, they will react chemically with alkaline hydroxides. or alkaline ferrous at ordinary temperatures to form or help form compounds that possess cementitious properties. Examples of pozzolanic additives may include Class C fly ash from burned lignite coal, Class F fly ash from burning bituminous coal, fly ash from pulverized fuel, fume from condensed silica, metakaolin, rubber ash, and waste glass. The additives found in cement are particularly useful for increasing the mass of the resulting door member. Insulating gases can replace trapped air to provide greater insulation. These gases include molecules that generally have a higher atomic mass than air. Possible examples include halocarbons and hydrocarbons, such as HCFC-22, HFC-135a, HFC-245fa, HFC-365mfc; noble gases, such as argon, xenon, and krypton; sulfur hexafluoride; hydrocarbons, such as pentane; and mixtures thereof. The process for introducing the insulating gas into the foamed cement suspension is discussed below. The door members 12 can be formed without the use of a door frame 14. As shown in the embodiment illustrated in Figure 2, concrete or cement tiles having relatively low group values and relatively low flow rates can be molded. Foamed cement suspensions suitable for this purpose include those having a fluidity of about 12.26 cm (4,825 inches) to about 45.72 cm (18 inches) using the flow method TT. The flow method TT includes preparing a closed-ended Southern Yellow Pine box that includes a deposit. The box is treated with polyvinylidene chloride, preferably PERMAX 803, for seal purposes. The box is preferably at least 66.04 cm (26 inches) long. The reservoir is preferably a 15.24 cm x 15.24 cm x 15.24 cm (6 inches x 6 inches x 6 inches) cube with a non-porous sliding door leading to the flow channel. The box is placed on a level surface. The foamed cement suspension to be tested for fluidity is poured into the reservoir and is still tested with the 15.24 cm (6 in) high mark. The sliding door opens with any scraped foamed cement slurry towards the tank. The foamed cement suspension is allowed to flow into the channel. The furthest distance of flow from the sliding door is measured after 1.0 minute. The slabs are formed by pouring a suspension 60 of foamed cement with a relatively low sink value and a relatively low flow rate through the nozzle 62 into a shape 64, preferably an open face shape. The open face shape is preferably placed on a horizontal band 66 before the foamed cement suspension 60 is poured. The mechanical disperser 68 is preferably used to distribute the foamed cement slurry in the open face shape and to prepare the cured foamed slurry suspension for the door frame. Other suitable devices for distributing and preparing the foamed cement suspension include cones and enhancement units. Once the foamed cement slurry is cured, the resulting door member is released from the open face shape. The shape can be constructed of ultra high molecular weight polyethylene, high density polyethylene, polypropylene, polycarbonate, polyvinylidene chloride or any other material that does not readily adhere to the foamed cement slurry. The Hardie Plank machine available from James Hardie Company of Australia can be used to form continuous molded polymer cement board slabs. In addition, the Cemplank machine or the Cembord machine, both available from Cemplank, Inc. De Blandón Pennsylvania can be used to form continuous polymer cement board slabs. The door members that are molded into the open face shape can be secured to a door frame through adhesives. The fixing means are understood to include, but are limited to, fasteners, adhesives, press fittings, plastic or metal welding, intersubjects and press fit devices. For example, as illustrated in Figure 3, the housing 72 can be secured on the door member 74. It is understood that housings mean receptacles for receiving core materials wherein the marginal edges are present or can be formed by temporary external means and the second skin surface is fixed on at least one side to the marginal edge or can be connected in a step of subsequent process. The accommodations are understood to include, but are not limited to, multi-sided trays with lids, tubes, tubes that conform to temporary external fittings, bags, cassettes with multiple sides that are bent, folded over or folded in advance and are they secure with a superior flap that is secured in a subsequent processing step. As illustrated in Figure 4, an aesthetic layer 78 can be applied to the door member 80. Examples of a specific type of aesthetic layers, aesthetic wood-like surface layers, may include wood veneers, decorative films that simulate wood finishes, transcribed pigment layers, wood clad with polyvinylidene chloride, and organic polymer cladding. An example of a decorative film that simulates a wood finish is an extruded sheet containing dyes that liquefy at different temperatures, as described in the U.S. Patent. No. 5,866,054. An example of a transcribed pigment layer is FINAL FINISH, a product available from Immersion Graphics, Inc. of Columbus, Georgia. It is understood that before applying the wood-like aesthetic surface layer, a finishing sanding or other smoothing process can be used to minimize the minor imperfection on the surface of the door member. A wood-like texture can be molded towards the door member. There are many processes to produce wood-like textures. For example, a silicone rubber master or polymer film can be constructed from a model door skin. In addition, the following processes can be used: a steel master engraved with acid can be constructed from a photoresist, nickel chemical vapor deposition can be used, and masters engraved by hand or with machine made of wood, metal, ceramic, or polymer they can be used. In addition, a decorative fiberglass fabric with wood grain, available from Lance Brown Import-Export can be molded towards the door member. Alternatively, the wood-like texture may be a thin-sheet stainless steel bag, available from McMaster-Carr. The thin sheet stainless steel bag is appropriately configured to have similar edges at the door. In addition, an insertable gate member can be CNC machined and coated with a top coat, primer or sealant. Another embodiment of the present invention is illustrated in Figure 5 as having a previously pigmented plastic door frame 84. Preferably, the previously pigmented plastic door frame 84 is manufactured using a blow molding method. However, it is understood that other manufacturing processes can be used depending on the application. These manufacturing processes may include rotomolding, sheet extrusion, injection molding or thermoforming. A particularly useful sheet extrusion method includes forming a biaxially oriented blade, trimming and grooving the biaxially oriented blade, and fastening a previously formed door member to the biaxially oriented blade using adhesives or ultrasonic welding. A particularly useful injection molding process includes injection molding sections of the door frame and securing the sections together to form the door frame. Examples of pre-pigmented plastics include polystyrene, polyvinyl chloride, polyethylene terephthalate, polyolefins, nylon, ABS, ABS- (ABS-fiberglass) -ABS compounds, long-fiber thermoplastics, reinforced plastics, and mixtures of these plastics. . Preferably, ABS is used. The previous pigmentation provides a uniform surface color and the paint is not necessary. An elongated insert 86 may be positioned along the inner edge 88 through a hole 90, as illustrated in Figure 5. The elongate insert 86 may be up to the height of the previously pigmented plastic door frame 84. The first articulation plate 92 and the second articulation plate 94 can be secured to the elongate insert 86 using a screw, nail, or similar fastener. The clamping apparatus 96 can be secured to the clamping insert 98 using a screw, nail or similar fastener. A first set of hollow inserts 102 and a second set of hollow inserts 104, as illustrated in Figures 6 and 7, can be inserted into the previously pigmented plastic door frame 84 after the door member is placed within the interior door cavity or the foamed cement suspension is cured inside the interior door cavity. As illustrated in Figure 7, inserts 102 and 104 are screwed to the door member and held in place by screw threads 78. The first articulation plate 92 and the second articulation plate 94 can be secured to inserts 102 and 104 using a screw, nail or similar fastener. Two inserts are shown for simplicity. The number and spacing of the inserts will depend on the style of the articulation plate that is going to be fixed to it. Figure 8 illustrates a preferred method for filling the interior door cavity with the foamed cement slurry and cured the foamed cement slurry to produce the gas-entrained cementitious core. It is understood that a non-ceramic, flexible composite can be introduced into the interior door cavity before filling to improve the flexibility of the resulting high-performance door. According to Figure 8, a bank 110 of door frames is placed on the platform 112 with an orientation so that the rails are parallel with the ground. Preferably, the first rail includes a pour hole 114. It is understood, however, that the door frames can be placed in any orientation that leads to introducing the foamed cement suspension into the interior door cavity. These orientations include, but are not limited to having vertical uprights parallel to the ground and having door skins parallel with the ground. After being placed on the platform 112, the series 110 of door frames are fastened to the fitting 16, using a pressure scale between about 0.1 lbf / in2 and about 20 lbf / in2. Preferably, the fitting 116 utilizes a pressure range of between about 0.5 lbf / in2 and about 2.0 lbf / in2. Accessories suitable for use with the present invention include a platen press, a blister press, a slot press, a rolling line, and an edge clamp. Preferably, the fitting 116 is comprised of a platen press having platens 118 and 120. The temperature of the platens may be between about -2 ° C and about 95 ° C. Preferably, the temperature of the plates is between about 20 ° C and about 30 ° C. The nozzle 122 is preferably inserted into the interior door cavity through the pour hole 114. Preferably a plurality of holes and ventilation slots are included in the lower end rail to prevent significant pressure during pouring of the foamed cement slurry. It is also understood that no end rail is required during the pour and may be added later or not at all. The nozzle 122 delivers the foamed cement suspension to the interior door cavity. The foamed cement suspension can be transferred to the inner door cavity incrementally, using between 1 and 5 increments. Preferably, 1 to 3 increments are used to fill the interior door cavity 16 with the foamed cement suspension. More preferably, 1 increment is used to fill the interior door cavity 16. Alternatively, as illustrated in Figure 9, the filling process may include positioning the door frame 128 so that the door skins are generally parallel to the ground. After the inner door cavity is filled with the foamed cement slurry, a set of rollers 130 can be run over one of the door skins 132 to remove excess cement-trapped material 134 from the interior door cavity. . If the foamed cement suspension includes an insulating gas, the following procedure is preferably used. The foaming agent is pre-mixed in an evacuated pressure vessel. The insulating gas is introduced into the evacuated pressure vessel. The other ingredients, which may include cement, water, setting accelerator, and water reducer, are mixed in a colloidal mixer and lath mixer that are enclosed and evacuated to limit the air pressure. Once the other ingredients are sufficiently mixed in the evacuated strip mixer, the previously mixed foaming agent / insulating gas mixture is introduced. The door skins are preferably secured to the walls of a retention fitting by evacuating the retention fitting. The door frame preferably has a first rail with a pouring hole. An air grip is placed in the pour hole, and the interior door cavity is evacuated after the evacuation of the retaining fitting. The vacuum pressure between the accessory vacuum retaining the skin and the retaining accessory walls is at least about 1 mm Hg greater than the vacuum of the inner door cavity. The foamed cement suspension, which contains the trapped insulating gas, is then pumped into the interior door cavity through the air retainer, minimizing contamination of the suspension with ambient air.
The pore size of trapped insulating gas or air can be influenced. During curing, the fitting can be heated in a convection, dielectric or microwave oven until the cementitious reaction has been allowed to cement to form a structurally stable cell wall around the trapped gas and / or air bubbles. The residence time in the furnace necessary to achieve a stable cell wall depends on the formulation of the foamed cement suspension, including the cement and setting accelerator used, and the temperature of the furnace. For air, the temperature of the furnace can vary from about 1 ° C to about 70 ° C above the ambient, preferably around 10 ° C to about 40 ° C, and more preferably around 20 ° C to about 35 ° C. C. For other gases, the scale can vary depending on the mass and molecular weight of the insulating gas. During the curing process, a hydration reaction occurs within the foamed cement slurry. This reaction increases the amount of heat in the interior door cavity. In a typical 110-door bench 110 placed within the fixture, the foaming cement suspension temperature in the interior door cavity can reach approximately 60 ° C above the ambient within approximately six hours of curing. After a structurally stable cell wall is achieved, cooling may be added to reduce the excess pressure of the expanded trapped gas. Conventional thermal exchangers can be used to conserve energy during this process. Air vibrators 124 and 126 can be fixed to the fitting 116 to induce improved flow and consolidation of the foamed cement suspension. In order to avoid gaps caused by the foaming of the suspension of foamed cement. Air vibrators 124 and 126 can also help decrease the flow viscosity in foamed cement suspensions including thixotropic agents. Preferably, a US13 air vibrator, available from Global Manufacturing of Little Rock, Arkansas, can be employed. Preferably, the air vibrator US13 is employed for between about 2 seconds to about 30 seconds. More preferably, the air vibrator US13 is employed for between about 5 seconds to about 10 seconds, during each incremental addition of the foamed cement suspension. If the door skins are constructed of fiberglass and the tensile strength of the skins is less than about 1.0 x 106 lbf / in2, it is preferable to apply a vacuum from the fitting 116 to the external surface of the door skins at In order to keep the door skins flat during pore formation. The fixture draws vacuum from approximately 0.35 kg / cm2 to approximately 1.42 kg / cm2 (5 psi at 20 psi). The accessory surfaces preferably have slots to allow air trapped in the vacuum ports to escape out of the edges of the fitting. Once the inner door cavity is filled with the foamed cement suspension, a cover can be secured to the first rail. The filled door frame can be covered with a top rail made of thermoplastic polymer, thermosetting polymer, or metal. Alternatively, the lid can be constructed of cuttable wood, optionally coated with a waterproof coating, preferably PERMAX 803, produced by Noveon, Inc., Cleveland, Ohio. Once the inner door cavity is filled with the foamed cement slurry, the foamed cement slurry is allowed to cure in the accessory 116. The foamed cement slurry reaches an initial setting point once it resists subsidence, or passes through a maximum exothermic generated during the hydration reaction, whichever comes first. After reaching the initial setting point, the foamed cement slurry is further cured to reach a final setting point at which the door can be moved without damaging the door member. Depending on the foamed cement suspension formulation, the initial setting point and the final setting point vary. In Example 3 below, the exothermic temperature profiles are provided for two different formulations, showing variations in the initial and final setting points. Using the method of ASTM C-403, the door can be separated from the fittings when the penetrometer indicates that the foamed cement suspension of Example 1 achieves a strength of approximately 70 lbf / in2. It is also understood that these compression resistances are not identical with compression strength measurements obtained by ASTM C-39 (results described below). Depending on the formulation, the foamed cement suspension can be cured in the fixture for a period of between about 1 minutes and about 48 hours. Preferably, the curing time in the accessory is between about 5 minutes and about 24 hours. More preferably, the curing time in the accessory is between 10 minutes and approximately 24 hours. The process of curing the suspension until the door can be separated from the attachment without damage is termed as green resistance curing. To reduce the curing time, a quick curing setting accelerator can be added to the foamed cement slurry. The fast curing setting accelerator is preferably injected into the foamed cement suspension stream at the end of the nozzle 122 with a discharge tube. The discharge tube preferably includes a check valve to minimize backward flow of the foamed cement suspension to the discharge tube. The typical fast curing setting accelerator has a basic pH of between about 11 and about 13. General examples include aluminum based accelerators, modified sodium silicate based accelerators, liquid alkali based accelerators and oxide-based alkali free accelerators. of calcium. These accelerators are discussed in the Patents of E.ü.A. 6,221,151 and 6,025,404, which are incorporated by reference. The curing time is reduced to between about 2 minutes to about 10 minutes using the fast curing setting accelerator. After leaving the fitting, the foamed cement suspension can be further cured to achieve increased strength and final setting. The curing time after leaving the fitting may be from about 0 days to about 100 days, preferably about 3 to about 28 days, and more preferably about 10 days to about 28 days. The typical scale of compressive strengths measured using ASTM C-39 of a door member constructed of the foamed cement suspension is about 58 lbf / in2 to about 75 lbf / in2. Having generally described the present invention, further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified. EXAMPLE 1 AND COMPARATIVE GRAPH A A preferred foamed cement suspension of the present invention that is capable of being cured for use as a door member comprises the following: Component As is / Dry Weight% Hydraulic Cement 61.43%
Water 26.30%.
Foaming solution 9.22% Water reducer 0.01% Accelerator of setting 0.04% Reinforcement fibers 0.18%
Expanded polystyrene beads 2.82% Table 1 The preferred hydraulic cement is Type III Portland Cement, produced by Lone-Star Industries, Inc., of Indianapolis, Indiana. The preferable water is running water. The foaming solution is preferably comprised of 1 part of foaming agent and 40 parts of water. The preferred foaming agent is liquid MEARLCRETE foam concentrate, produced by Cellular Concrete LLC of Roselle Park, New Jersey. The preferable water reducer is RHEOBUILD 100, produced by Master Builders Technologies of Cleveland, Ohio. Preferred reinforcing fibers are 3/4"long STEALTH polypropylene fibers produced by the Fibermesh Division of Synthetic Industries of Chattanooga, Tenn. The preferred nominal diameter of the expanded polystyrene beads is 6.35 mm (1). / 4") and are available from the Cellofoam Company of Converys, Georgi. A preferred method for mixing the ingredients of the foamed cement suspension comprises the following steps. Water, hydraulic cement, setting accelerator, and reinforcing fibers are added to a colloidal mixer supplied by Chem Grout of LaGrange Park, Illinois. Preferably, all four ingredients are added to the colloidal mixer in that order. By mixing the ingredients for at least 45 seconds (to ensure substantial mixing of the hydraulic cement and water), the water reducer is added to the colloid mixer. Waiting at least 45 seconds to add the water reducer, the effectiveness of the water reducer is greatly improved. After mixing the water reducer with the other four ingredients, the contents of the colloidal mixer are transferred to a lath mixer preferably supplied by Chem Grout of LaGrange Park, Illinois. In a foaming agent mixer, the foaming agent, water and air are mixed to form the foaming solution. Preferably, the foaming solution is added to the ribbon mixer, with the addition of the expanded polystyrene beads following. The ribbon mixer is preferably modified to include bars t to help mix the contents in the ribbon mixer. A preferred method for transferring and curing the foamed cement suspension comprises the following steps. Before the interior door cavity is filled with the foamed cement suspension, the door frame is clamped to a platen press using a force of approximately 0.5 lbf / in2 to approximately 2.0 lbf / in2. The temperature of the platens is on the scale of about 20 ° C to about 30 ° C. Once the contents of the ribbon mixer are substantially mixed, a Moino pump is preferably used to pump the foamed cement slurry into the interior door cavity. The Moino pump does not exclusively compress air bubbles trapped in the foamed cement suspension so as to destroy the foaming action of the foaming solution. The foamed cement suspension is transferred to the door frame in 1 to 5 increments, preferably 1 to 3 increments, and more. preferably 1 increase until the interior door cavity is filled. The full door is allowed to cure on the platen press until the foamed cement slurry does not sink. The curing time in the press accessory is preferably from about 6 hours to about 10 hours. It is also understood and preferable to transfer foamed cement slurry and fill the inner door cavity by means of a gravity feed system. In this system, the contents of the batten mixer are poured under the force of gravity into a hopper. The hopper is placed mechanically on the door cavity inside. The foamed cement suspension is allowed to flow from the hopper into the interior door cavity. The advantage of this system is the reduction of cost limiting the destruction of bubbles that pass through the compression phase of the pump. Various foaming agents were tested using the foamed cement suspension of Example 1 and replacing various foaming agents. One test included pouring the foamed cement suspension onto a column approximately 304.8 cm high (10 feet)For approximately 11.43 cm (4.5 inches) in diameter, the suspension is flush with the top of the column.The most preferable foams allow the foamed cement slurry to become permanently angry or expand by more than about 2 millimeters during setting so that the cement column is actually higher than the top of the column when observed after approximately 8 hours of curing Another test includes foaming various air foaming agents in an 18.95 liter bucket container (five gallons) HDPE Preferably, a "Junior" foam generator supplied by EAB Associates, Altrincham, United Kingdom is used to foam the foaming agent.A plate load of 85 grams with a diameter of approximately 13.34 cm (5.25) inches) is placed on the foam, if the load remains visible above the foam after about an hour, otherwise designated as time of persistence, the foam is suitable for the manufacture of at least 243.92 cm (8 feet) high doors. The following table includes the test results for various foaming agents Foaming agent Agent Type Expansion of Foaming time expansion persistence (hours) EABASSOC Synthetic N / A 0.5 PS 1262 Protein-based Shrinkage 3 Mearlcrete Protein-based Expansion >; 3 AFTC101251 Synthetic Expansion > 3 RHEOCELL 15 Synthetic N / A 0.2 Graph A It should be understood that column expansion was not measured for EABASSOC and RHEOCELL. 15 since the persistence time was too short to accommodate said measurement. EABASSOC is available from EAB Associates of Altrincham, United Kingdom. The foaming agent PS 1262 is available from Master Builders Technologies of Cleveland, Ohio. Mearlcrete is available from Cellular Concrete L.L.C., of Rosello Park, New Jersey. AFTC101251 is available from Applied Foam Tech Corporation of Harleysville, Pennsylvania. RHEOCELL 15 is available from Master Builders Tech. Synthetic foaming agents are suitable for use with superplasticizers to increase the fluidity of the foamed cement slurry. A preferred combination of foaming agent and superplasticizer is RHEOCELL 30 and RHEOBUILD HRWR 3000 FC. EXAMPLE 2 Example 2 is a low cost variation of the foamed cement suspension in Example 1. To reduce the cost of the foamed cement suspension, a foaming solution is replaced by expanded polystyrene beads. The foamed cement suspension of Example 2 comprises the following: Component As is / Dry Weight%
Hydraulic cement 59.20% Water 25.33% Foaming solution 15.24% Water reducer 0.01% Setting accelerator 0.04% Reinforcement fibers 0.18% Table 2 Preferred ingredients are the same as the preferred ingredients of Example 1. The preferred mixing process for the variation The low cost of the foamed cement slurry is similar to the mixing process of Example 1, except that the expanded polystyrene beads are not added to the ribbon mixer. The preferred method for transferring and curing the low cost variation of the foamed cement suspension is similar to the transfer and cure process of Example 1, except that the preferable curing time in the press fitting is between about 16 hours and about 24 hours. hours. This example passes both fire tests ASTM 2070-00 and BSI 476/22. Comparative Graph B provides density gradient data for examples 1 and 2. Height from Density lb / in3) Density Column Fund Example 2 Example 0 ft 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 Graph B EXAMPLE 3 AND COMPARATIVE GRAPHICS CF A preferred foamed slurry suspension of the present invention includes Type I Portland Cement hydraulic cement. Type I Portland Cement is a low-cost alternative. cost to Type III Portland Cement since Type I is not as finely ground as Type III. The preferred cement suspension of Example 3 is comprised of Components As Is / Dry Weight% Hydraulic Cement 61.04% Water 26.88% Foaming Agent 7.99% Water Reducer 0.02% Accelerator 0.04% Polypropylene Fibers 0.18% Expanded Polystyrene Beads 2.85% Table 3 The preferable ingredients are the same as the preferred ingredients of Example 1, except that the preferred hydraulic cement is Type I Portland Cement produced by Lone-Star Industries, Inc. of Indianapolis, Indiana. The preferred mixing process for the foamed cement suspension of Example 3 is similar to the mixing process of Example 1. The preferred method of transferring and curing the foamed cement suspension of Example 3 is similar to the transfer and cure process of Example 1 , except that the preferable curing time in the press accessory is between about 16 hours and about 24 hours. It is understood that this curing process can be accelerated by increasing the curing temperature above the ambient temperature. At a curing temperature of approximately -1 ° C (30 ° F) above ambient temperature, curing times are reduced by 50%. Type III Portland Cement is a finer-grained cement than Type 1. As a result, the foamed cement suspension using Type III achieves its final setting point approximately two hours earlier than the foamed cement suspension of the Type III cement. I. The exothermic temperature profiles of the two foamed cement suspensions confirm these results: Time (min.) Example 1 (using Example 3 (using Type III) (° C) Type I)) (° C) 0 20 18 30 21 20 60 22 21 90 22 23 120 23 24 150 25 (initial setting) 26 180 27 28 210 29 31 240 32 35 270 66 40 (Final setting)
300 44 45 330 47 48 360 48 49 390 49 (final set) 49 420 48 49 450 47 48 Graph C EXAMPLE 4 A preferred foamed cement suspension of the present invention which is capable of being cured for use as a door member and is Particularly suitable as a fire resistant door comprises the following: Component As Is / Dry weight% Hydraulic cement 65.59% Water 28.67% Foaming solution 3.95% Water reducer 0.01% Accelerator 0.04% Polypropylene fibers 0.33% Expanded polystyrene beads 1.42% Frame The preferable ingredients are the same as the preferred ingredients of Example 3, except that the preferred foaming agent is RHEOCELL 15, available from Master Builders Technologies, of Cleveland, Ohio and the preferable water reducer is RHEOBUILD HRWR 2000 FC, available from Master Builders Technologies, of Cleveland, Ohio. The preferred mixing process for the foamed cement slurry of Example 4 is similar to the mixing process of Example 1. The preferred method for transferring and curing the foamed cement slurry of Example 4 is similar to the transfer and curing process of Example 1 , except that the preferable curing time in the press accessory is between about 16 hours and about 24 hours. The fire resistant door using the preferred foamed cement suspension of Example 4 passes the 20 minute ASTM 2074-00 positive pressure fire test and the 3Q minute BSI 476/22 positive fire test. EXAMPLE 5 A preferred foamed cement suspension of the present invention that is capable of being cured as a member of. door and has a relatively low sink value and a relatively low flow rate: Components As Is / Dry Weight%
Hydraulic cement 61.43% Water 26.30% Foaming solution 9.22% Water reducer 0.01% Setting accelerator 0.04% Polypropylene fibers 0.18% Expanded polyester beads 2.82% Table 5 The preferred ingredients are the same as the preferred ingredients of Example 1. The process Preferred mixing for the foamed cement slurry of Example 5 is similar to the mixing process for Example 1.
The foamed cement suspension is suitable for continuously molding slabs in a horizontal band to an open face shape, using a hydrostatic head pressure feed of at least about 182.94 cm (6 feet). A mechanical disperser, cone, or etching unit is preferably used to distribute the foamed cement suspension in the form and prepare the cured foamed cement slurry for the door frame. The preferred curing time in the open face form is between about 8 hours and about 16 hours. EXAMPLE 6 A preferred high performance door of the present invention is constructed to inhibit the transfer of heat through the door member during a fire. The preferred high performance door according to this example limits the temperature of the door surface not exposed to fire to 250 ° C after 3 'minutes, using the ASTM E-152 standard. The door frame is constructed of SAE 1010 carbon steel or similar material. The door member is comprised of a cured foamed cement suspension. The suspension of foamed cement is comprised of: Component As Is / Dry Weight% Hydraulic cement 65.14% Water 24.43% Foaming solution 10.07% Water reducer < 0.01% Setting Accelerator 0.02% Polypropylene Fibers 0.33% Table 6 Preferred ingredients are the same as the preferred ingredients of Example 3. The preferred mixing process for the foamed cement slurry of Example 6 is similar to the mixing process of Example 2. The foamed cement suspension is transferred to a shape, which is sized similar to the door frame. The shape is preferably made of ultra high molecular weight polyethylene material. The shape can have etching patterns to match patterns present in a door frame. The foamed cement suspension is transferred to the shape in 1 to 5 increments, preferably 1 to 3 increments, and more preferably 1 increment until the form is filled. After curing the foamed cement slurry in the form for about 10 days to about 28 days, the cured foamed cement core, or door member, is separated from the shape. An adhesive is applied to the door member sufficient to retain the door member to the interior of the steel door frame. In addition, sufficient adhesive is applied to the door so that the slam dunk durability tests required by code survive (A SI / ISDI 105). A typical test requires the door to last 1,000,000 slamming cycles and the adhesive must be applied to at least 70% of the surface area of the insulating core member. Preferably, the adhesive is an elastomeric latex adhesive, such as PPG TRIMBOND T7850, available from PPG Industries. Other adhesives include hot melt polyurethane, epoxy, and structural silicon caulking. EXAMPLE 7 A preferred method for producing a high performance door of the present invention includes transferring a fast cure curing accelerator towards the inner door cavity to greatly reduce the curing time. The foamed cement suspensions of Examples 1-6 can be used in the fast curing method of Example 7 if the curing accelerator of Examples 1-6 is replaced with the fast curing setting accelerator. The preferable quick curing setting accelerator is shotcrete, otherwise called gunite, available from several suppliers. The preferred mixing process for the fast curing method is similar to the mixing processes of Examples 1-6, except that the setting accelerator is not added to the colloid mixer.A preferred method for transferring and curing the foamed cement suspension comprises the following steps. Once the contents of the ribbon mixer are substantially mixed, a Moino pump is preferably used to pump the foamed cement slurry into the inner door cavity or the open face shape. The Moino pump does not excessively compress the air bubbles trapped in the foamed cement suspension in such a way as to destroy the foaming action of the foaming solution. The fast curing setting accelerator is preferably injected into the foamed cement slurry as the suspension leaves the Moino pump in a nozzle head. Preferably, a discharge tube is used to inject the quick curing setting accelerator. In order to prevent the backflow of the foamed cement suspension towards the discharge pipe, the end of the discharge pipe preferably includes a check valve. The setting time is preferably from about 2 minutes to about 10 minutes. COMPARATIVE EXAMPLE 8 In foamed cement suspension formulations containing expanded polystyrene beads, an optimum amount of foaming solution must be added to reduce the destruction of foam bubbles trapped in the foamed cement slurry. The following table describes a suspension of foamed cement containing 37 parts by volume of expanded polystyrene beads to 63 parts by volume of foaming solution Component As Is / Dry Weight%
Hydraulic cement 61.43% Water 26.29% Foaming solution 9.22% Water reducer 0.01% Setting accelerator 0.04% Polypropylene fibers 0.18% Expanded polystyrene beads 2.82% Table 7 If the formulation is used in Table 7, 22.8 additional parts should be added in volume of foaming solution in relation to the volume of expanded polystyrene beads to reach the optimum level of foaming solution. The following table describes a suspension of foamed cement containing 18 parts by volume of polystyrene beads expanded to 82 parts by volume of foaming solution: Component As This / Dry Weight%
Hydraulic cement 61.02% Water 26.12% Foaming solution 11.26% Water reducer 0.01% Setting accelerator 0.04% Polypropylene fibers 0.18% Expanded polystyrene beads 1.37% Table 8 If the formulation is used in Table 8, 14 additional parts should be added in volume of foaming solution in relation to the volume of expanded polystyrene beads to reach the optimum level of foaming solution. Although embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without abandoning the spirit and scope of the invention.
(4,825 inches) and approximately 45.72 cm (28 inches) when tested using the TT fluidity method; molding the cementitious material trapped in gas to a shape; let the cementitious material trapped in gas achieve green resistance curing; and separating the gas-entrained cementitious material from the form in which the gas-entrained cementitious material provides a core of gas-entrained cementitious material to be used in conjunction with a door. 27.- A method to form a high performance door, the method comprises: providing a door frame having a generally flat construction with marginal edges and at least one door skin that helps to define an interior door cavity; place the door frame in an accessory; filling the interior door cavity with a cementitious material trapped in gas; cure in green resistance the cementitious material trapped in gas; and separating the door frame from the fixture wherein the cementitious material trapped in cured gas provides a core of gas-entrained cementitious material to be used in conjunction with a door.