HK1208714B

HK1208714B - Fire rated door core and door

Info

Publication number: HK1208714B
Application number: HK15109402.6A
Authority: HK
Inventors: 埃文‧R‧丹尼尔斯; 乔纳森‧纽顿
Original assignee: 知识产权古里亚有限责任公司
Priority date: 2012-06-29
Filing date: 2013-06-28
Publication date: 2017-08-18

Description

Fireproof door core and fireproof door

Technical Field

The present invention relates generally to the field of door manufacturing, and more particularly to fire resistant door cores and fire resistant doors.

Background

Many methods and techniques have been developed for the manufacture of fire rated doors and fire rated door cores for a long time. Most of these prior art designs are not well suited for fully automated manufacturing processes. Furthermore, prior art fire rated doors are expensive and require a mineral core. The core may be exposed in the routed portion and may reduce the strength of the door due to the reduced thickness of the door panel. In addition, alignment of the door panels during assembly can be cumbersome and require additional finishing after assembly to square the door. Therefore, there is a need for a fire rated door and fire rated door core that does not suffer from these drawbacks.

Disclosure of Invention

The door of the present invention provides the fire resistance required to obtain the necessary fire certification. The fire rated door includes a fire rated door core having typical dimensions of 3 and 4 feet in width and having a length ranging from 7 to 10 feet. The thickness of the door core may range from 1.50 inches to 2.00 inches. In some cases, the sides and ends of the fire door core may be fitted with exterior cladding strips. In other cases, an expansion strip may be added between the wrap strip and the fire door core.

More particularly, the present invention provides a fire rated door including a core, a first trim panel, and a second trim panel. The core includes: (a) a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made from a first fire resistant material, and (b) an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made from a second fire resistant material having a higher density than the first fire resistant material. A first trim panel is attached to the top of the fire resistant center panel and the extruded fire resistant border. A second trim panel is attached to the bottom of the fire resistant center panel and the extruded fire resistant border.

Additionally, the present invention provides a method of manufacturing a fire rated door including providing a core, attaching a first trim panel to a top portion of the core, and attaching a second trim panel to a bottom portion of the core. The core is provided by providing a fire resistant center panel, attaching a first stile of an extruded fire resistant border to a first side of the fire resistant center panel, attaching a second stile of an extruded fire resistant border to a second side of the fire resistant center panel, attaching a first rail of an extruded fire resistant border to a first end of the fire resistant center panel and to the first and second stiles of the extruded fire resistant border, and attaching a second rail of an extruded fire resistant border to a second end of the fire resistant center panel and to the first and second stiles of the extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made from a first fire resistant material. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.

Additionally, a method of manufacturing a fire rated door is provided that includes providing a core, attaching a first trim panel to a top portion of the core, and attaching a second trim panel to a bottom portion of the core. The core is provided by providing an extruded fire resistant border having a central void, filling the void within the extruded fire resistant border with a first fire resistant material having a lower density than a second fire resistant material to form a fire resistant center panel, and baking the extruded fire resistant border and the first fire resistant material. An extruded fire resistant jamb is provided by providing a first stile of an extruded fire resistant jamb, attaching a first rail of the extruded fire resistant jamb to the first stile of the extruded fire resistant jamb, attaching a second rail of the extruded fire resistant jamb to the first stile, and attaching the second stile of the extruded fire resistant jamb to the first and second rails of the extruded fire resistant jamb. The extruded fire resistant border is made of a second fire resistant material.

The present invention is described in detail below with reference to the accompanying drawings.

Drawings

The above and other advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which:

figure 1 is a perspective view of a door core for a fire rated door in accordance with one embodiment of the present invention;

figure 2 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

FIGS. 3A-3D are cross-sectional views of various interfaces of a center plate and a bezel of a door core according to one embodiment of the present invention;

figure 4 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 5 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 6 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 7 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 8 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 9 is a perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 10A is an exploded perspective view of a door core for a fire rated door in accordance with another embodiment of the present invention;

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

figure 11A is an exploded perspective view of a fire rated door in accordance with one embodiment of the present invention;

figure 11B is a cross-sectional view of the fire rated door of figure 11A;

figure 11C is a cross-sectional view of an alternative form of the fire rated door of figure 11A;

figure 12A is an exploded perspective view of a fire rated door in accordance with another embodiment of the present invention;

figure 12B is a cross-sectional view of the fire rated door of figure 12A;

figure 13A is an exploded perspective view of a fire rated door in accordance with another embodiment of the present invention;

figure 13B is a cross-sectional view of the fire rated door of figure 13A;

figure 13C is a cross-sectional view of an alternative form of the fire rated door of figure 13A;

figure 14A is an exploded perspective view of a fire rated door in accordance with another embodiment of the present invention;

figure 14B is a cross-sectional view of the fire rated door of figure 14A;

figure 14C is a cross-sectional view of an alternative form of the fire rated door of figure 14A;

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

figure 15B is a cross-sectional view of the fire rated door of figure 15A;

figure 16 is a flow diagram of a method of manufacturing a door core for a fire rated door in accordance with one embodiment of the present invention;

figure 17 is a flow chart of a method of manufacturing a door core for a fire rated door in accordance with another embodiment of the present invention;

figure 18 is a flow diagram of a method of manufacturing a fire rated door in accordance with one embodiment of the present invention.

Detailed Description

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention. The discussion herein is primarily directed to fire doors, but it is understood that the concepts of the present invention are applicable to any type of door.

The door core of the present invention provides the fire resistance necessary to obtain the necessary certification. The length and width of the fire resistant core will be adapted to the length and width specifications of the finished door. Typical dimensions for the refractory core are 3 feet and 4 feet wide, and have a length ranging from 7 feet to 10 feet. The thickness of the door core will typically be between 0.125 "(inches) and 1.5". A door manufacturer may use any of the complete core designs described herein as the fire resistant core of the manufacturer's fire rated door. Fire doors can be made with fire limits of 20-30, 45, 60, 90, or 120 minutes depending on the configuration and materials used. Manufacturers typically finish the finished door by adding a final piece of wood or veneer to the door to provide the aesthetic appeal of the product.

Referring now to figure 1, a perspective view of a door core 100 for a fire rated door in accordance with one embodiment of the present invention is shown. The door core 100 includes a fire resistant center panel 102 and an extruded fire resistant border 104. The fire resistant center panel 102 has a bottom (not shown), a top 106, a first side 108, a second side 110, a first end 112, and a second end 114. The fire resistant center panel 102 is made of a first fire resistant material that is either pourable or extrudable. The first refractory material may be comprised of gypsum, water, glass, ceramic material, cellulosic or fibrous material, and one or more binders. One non-limiting example of such a material is the StarLite product licensed by StarStone, Inc. (a subsidiary of E.Khasoggi Industries, Inc.). Other materials may also be used. The extruded fire resistant border 104 is made of a second fire resistant material having a higher density than the first fire resistant material so that the second fire resistant material has a retention capability (e.g., fasteners will attach to the second fire resistant material and remain fixed after installation) and can be formed using an extrusion process. The second refractory material may be comprised of water, gypsum, cellulosic or fibrous materials, glass, ceramic materials, and one or more binders. One non-limiting example of such a material is the StarStone product licensed by StarStone Inc. (a subsidiary of E.Khasoggi Industries, Inc.). Other materials may also be used. The extruded fire resistant border 104 may be formed from a molded piece of the second fire resistant material (as in fig. 1), or from a plurality of stiles and rails made of the second fire resistant material that are bonded or otherwise secured together (as in fig. 4). The extruded fire resistant border 104 is attached to the first side 108, the second side 110, the first end 112, and the second end 114 of the fire resistant center panel 102 using adhesives, fasteners, or a bonding process, such as pouring the first fire resistant material into a "mold" formed by the extruded fire resistant border 104. Several examples of the interface between the extruded fire resistant border 104 and the fire resistant center panel 102 are shown in figures 3A-3D.

The dimensions of the core 100 and other cores described below with reference to fig. 2-10, the fire resistant center panel 102 and the extruded fire resistant border 104 will vary depending on the particular application for which the door core is made. Typical dimensions include, but are not limited to, a thickness of 1.5 "to 2.0" for the fire resistant center panel 102 and the extruded fire resistant border 104, a total length of 7 '(feet) to 10' for the core 100, a total width of 3 'to 4' for the core 100, a width of 1 "to 3 for the top and bottom portions (rails) of the extruded fire resistant border 104, and a width of 1.0" to 3 "for the left and right portions (stiles) of the extruded fire resistant border 104 (e.g., 1.625").

Referring to fig. 2-10, the core 100 and other cores described below may be made by assembling the refractory rim 104, pouring a first refractory material into the area formed by the refractory rim 104, and baking the core 100. Alternatively, the core 100 may be made by making a sheet of the first fire resistant material and a sheet of the second fire resistant material using an extrusion process, sawing the sheet of the second fire resistant material with a gang saw to make stiles and rails of a fire resistant border, trimming the extruded stiles and rails to shape or cut them to a desired smoothness, size and shape, and bonding or fastening the stiles and rails of the fire resistant border to the fire resistant center panel 102.

Referring now to figure 2, a perspective view of a door core 200 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 200 includes a first fire resistant center panel 102a, a second fire resistant center panel 102b and an extruded fire resistant border 104. The first fire resistant center panel 102a has a bottom (not shown), a top 106a, a first side 108a, a second side 110a, a first end 112 and a second end 202. The second fire resistant center panel 102b has a bottom (not shown), a top 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire resistant center panel 102a and the second fire resistant center panel 102b are each made from the first fire resistant material that is either pourable or extrudable. The extruded fire resistant border 104 is made of the second fire resistant material having a higher density than the first fire resistant material so that the second fire resistant material has a holding capacity (e.g., fasteners will attach to the second fire resistant material and remain fixed after installation) and can be formed using an extrusion process. The extruded fire resistant border 104 also includes a central rail 206 made of a second fire resistant material. The extruded fire resistant border 104 may be formed from a molded piece of the second fire resistant material (as in fig. 2), or from a plurality of stiles and rails made of the second fire resistant material that are bonded or otherwise secured together (as in fig. 5). The extruded fire resistant border 104 (including the middle rail 206) is attached to the first side 108a, the second side 110a, the first end 112a, and the second end 202 of the fire resistant center panel 102a, and the first side 108b, the second side 110b, the first end 204, and the second end 114 of the second fire resistant center panel 102b using adhesives, fasteners, or a bonding process (e.g., pouring a first fire resistant material into a "mold" formed by the extruded fire resistant border 104). Several examples of the interface between the extruded fire resistant border 104 and the fire resistant center panels 102a, 102b are shown in figures 3A-3D.

The dimensions of the core 200 and other cores described below with reference to fig. 3-10, the fire resistant center panels 102a, 102b and the extruded fire resistant border 104 will vary depending on the particular application for which the door core is made. Typical dimensions include, but are not limited to, a thickness of 1.5 "for the fire resistant center panels 102a, 102b and the extruded fire resistant border 104, an overall length of the core 100 of 7 'to 10', an overall width of the core 100 of 3 'to 4', a width of the top, bottom and middle portions (rails) of the extruded fire resistant border 104 of 1" to 3 ", and a width of the left and right portions (stiles) of the extruded fire resistant border 104 of 1" to 3 "(e.g., 1.625).

Referring now to fig. 3A-3D, cross-sectional views of various interfaces of the center plate 102 and bezel 104 of door cores 100, 200, 400, 500, 600, 700, 800, and 900 are shown, in accordance with embodiments of the present invention. Figure 3A shows a straight interface where an adhesive is used to attach the extruded fire resistant border 104 to the fire resistant center panel 102. It should be noted that the flat seam can be inclined relative to the top of the fire resistant center panel 102 rather than being substantially vertical. As shown in fig. 3B-3D, the extruded fire resistant border 104 can be attached to the fire resistant center panel 102 by way of a set of male and female connectors 300 formed in the extruded fire resistant border 104 and the fire resistant center panel 102. The male and female connectors may be triangular 302 (fig. 3B), curved 304 (fig. 3C) or 306 (fig. 3D), rectangular, angled, tongue-and-groove, or combinations thereof. The extruded fire resistant border 104 is typically attached to the fire resistant center panel 102 with an adhesive, although fasteners or bonding processes may also be employed.

Referring now to figure 4, a perspective view of a door core 400 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 400 includes a fire resistant center panel 102 and an extruded fire resistant border 104. The fire resistant center panel 102 has a bottom (not shown), a top 106, a first side 108, a second side 110, a first end 112, and a second end 114. The fire resistant center panel 102 is made of a first fire resistant material that is either pourable or extrudable. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), and a second rail 408 (bottom). First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are all made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. The first stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are bonded or fastened together and to the fire resistant center panel 102. The first stile 402 (left side) is attached to the first side 108 of the fire resistant center panel 102 using an adhesive, fastener, or bonding process. The second stile 404 (right side) is attached to the second side 110 of the fire resistant center panel 102 using an adhesive, fastener or bonding process. The first rail 406 (top) is attached to the first end 112 of the fire resistant center panel 102 using an adhesive, fastener, or bonding process. The second rail 408 (top) is attached to the second end 114 of the fire resistant center panel 102 using an adhesive, fastener, or bonding process. Several examples of the interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panel 102 are shown in fig. 3A-3D.

Referring now to figure 5, a perspective view of a door core 500 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 500 includes a first fire resistant center panel 102a, a second fire resistant center panel 102b and an extruded fire resistant border 104. The first fire resistant center panel 102a has a bottom (not shown), a top 106a, a first side 108a, a second side 110a, a first end 112 and a second end 202. The second fire resistant center panel 102b has a bottom (not shown), a top 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire resistant center panel 102a and the second fire resistant center panel 102b are each made from a first fire resistant material that is either pourable or extrudable. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), a second rail 408 (bottom), and a third rail or insert 502 (middle). First stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 502 (middle) are all made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. The first stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 502 (middle) are bonded or fastened together and to the fire resistant center panels 102a and 102 b. The first stile 402 (left) is attached to the first side 108a, 108b of the fire resistant center panels 102a, 102b using an adhesive, fastener, or bonding process. A second stile 404 (right side) is attached to the second side 110a, 110b of the fire resistant center panels 102a, 102b using an adhesive, fastener, or bonding process. The first rail 406 (top) is attached to the first end 112 of the first fire resistant center panel 102a using an adhesive, fastener, or bonding process. The second rail 408 (bottom) is attached to the second end 114 of the second fire resistant center panel 102b using an adhesive, fastener or bonding process. The third rung or insert 502 (middle) is attached to the second end 202 of the first fire resistant center panel 102a and the first end 204 of the second fire resistant panel 102b using an adhesive, fastener, or bonding process. Several examples of interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panels 102a, 102b are shown in fig. 3A-3D. These interfaces can also be used between the fire resistant center panels 102a, 102b and the third rail or insert 502 (middle).

Referring now to figure 6, a perspective view of a door core 600 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 600 includes a fire resistant center panel 102, an extruded fire resistant border 104, and a lock bracket 602. The fire resistant center panel 102 has a bottom (not shown), a top 106, a first side 108, a second side 110, a first end 112, a second end 114, and a cutout or notch 604 disposed in the first side 108. The fire resistant center panel 102 is made of a first fire resistant material that is either pourable or extrudable. The lock bracket 602 is disposed within the cutout or notch 604 of the fire resistant center panel 102. The lock bracket 602 is made of a second refractory material and is sized to receive a door handle, lockset or other door hardware. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), and a second rail 408 (bottom). First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are all made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are bonded or fastened together and to fire resistant center panel 102 and lock seat 602. The first stile 402 (left side) is attached to the first side 108 of the fire resistant center panel 102 and the lock bracket 602 using an adhesive, fastener, or bonding process. The second stile 404 (right side) is attached to the second side 110 of the fire resistant center panel 102 using an adhesive, fastener or bonding process. The first rail 406 (top) is attached to the first end 112 of the fire resistant center panel 102 using an adhesive, fastener, or bonding process. The second rail 408 (top) is attached to the second end 114 of the fire resistant center panel 102 using an adhesive, fastener, or bonding process. Several examples of the interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panel 102 are shown in fig. 3A-3D. These interfaces may also be used between the lock bracket 602, the fire resistant center panel 102, and the first stile 402 (left).

Referring now to figure 7, a perspective view of a door core 700 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 700 includes a first fire resistant center panel 102a, a second fire resistant center panel 102b and an extruded fire resistant border 104. The first fire resistant center panel 102a has a bottom (not shown), a top 106a, a first side 108a, a second side 110a, a first end 112 and a second end 202. The second fire resistant center panel 102b has a bottom (not shown), a top 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire resistant center panel 102a and the second fire resistant center panel 102b are each made from a first fire resistant material that is either pourable or extrudable. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), a second rail 408 (bottom), and a third rail or insert 702 (middle). First stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 702 (middle) are made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. First stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 702 (middle) are bonded or fastened together and to the fire resistant center panels 102a and 102 b. The first stile 402 (left) is attached to the first side 108a, 108b of the fire resistant center panels 102a, 102b using an adhesive, fastener, or bonding process. A second stile 404 (right side) is attached to the second side 110a, 110b of the fire resistant center panels 102a, 102b using an adhesive, fastener, or bonding process. The first rail 406 (top) is attached to the first end 112 of the first fire resistant center panel 102a using an adhesive, fastener, or bonding process. The second rail 408 (bottom) is attached to the second end 114 of the second fire resistant center panel 102b using an adhesive, fastener or bonding process. A third rung or insert 702 (middle) is attached to the second end 202 of the first fire resistant center panel 102a and the first end 204 of the second fire resistant panel 102b using an adhesive, fastener, or bonding process. A third rail or insert 702 (middle) is positioned and sized (e.g., 5 "to 10" wide) to receive various accessories, such as bumper bars. Several examples of interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panels 102a, 102b are shown in fig. 3A-3D. These interfaces can also be used between the fire resistant center panels 102a, 102b and the third rail or insert 702 (middle).

Referring now to figure 8, a perspective view of a door core 800 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 800 includes a first fire resistant center panel 102a, a second fire resistant center panel 102b, an extruded fire resistant border 104 and a lock bracket 602. The first fire resistant center panel 102a has a bottom (not shown), a top 106a, a first side 108a, a second side 110a, a first end 112, a second end 202 and a cut or notch 604 disposed in the first side 108 a. The second fire resistant center panel 102b has a bottom (not shown), a top 106b, a first side 108b, a second side 110b, a first end 204 and a second end 114. The first fire resistant center panel 102a and the second fire resistant center panel 102b are each made from a first fire resistant material that is either pourable or extrudable. The lock bracket 602 is disposed within the cutout or notch 604 of the first fire resistant center panel 102 a. The lock bracket 602 is made from the second refractory material and is sized to receive a door handle, lockset or other door hardware. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), a second rail 408 (bottom), and a third rail or insert 702 (middle). First stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 702 (middle) are all made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. First stile 402 (left), second stile 404 (right), first rail 406 (top), second rail 408 (bottom), and third rail or insert 702 (middle) are bonded or fastened together and to the fire resistant center panels 102a, 102b and lock receptacles 602. The first stile 402 (left side) is attached to the first sides 108a, 108b of the fire resistant center panels 102a, 102b and the lock seat 602 using an adhesive, fastener or bonding process. A second stile 404 (right side) is attached to the second side 110a, 110b of the fire resistant center panels 102a, 102b using an adhesive, fastener, or bonding process. The first rail 406 (top) is attached to the first end 112 of the first fire resistant center panel 102a using an adhesive, fastener, or bonding process. The second rail 408 (bottom) is attached to the second end 114 of the second fire resistant center panel 102b using an adhesive, fastener or bonding process. The third rung or insert 702 (middle) is attached to the second end 202 of the first fire resistant center panel 102a, the first end 204 of the second fire resistant center panel 102b, and the lock bracket 602 using an adhesive, fastener, or bonding process. A third rail or insert 702 (middle) is positioned and sized (e.g., 5 "to 10" wide) to receive various accessories, such as bumper bars. Several examples of interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panels 102a, 102b are shown in fig. 3A-3D. These interfaces can also be used between the lock bracket 602, the fire resistant center panel 102a, the first stile 402 (left) and the third rail or insert 702 (middle).

Referring now to figure 9, a perspective view of a door core 900 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 900 includes a center panel 902 and an extruded fire rated border 104. The center plate 902 has a bottom (not shown), a top 106, a first side 108, a second side 110, a first end 112, and a second end 114. The central panel 902 is made from a corrugated filler (e.g., cardboard, etc.) having a plurality of voids (e.g., honeycomb, hexagon, triangle, etc.) and may be filled with an acoustical insulating material (e.g., fiberglass, foam, etc.). Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), and a second rail 408 (bottom). First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are bonded or fastened together and to center plate 902. A first stile 402 (left) is attached to the first side 108 of the center panel 902 using an adhesive, fastener, or bonding process. The second stile 404 (right side) is attached to the second side 110 of the center panel 902 using an adhesive, fastener, or bonding process. The first rail 406 (top) is attached to the first end 112 of the center panel 902 using an adhesive, fastener, or bonding process. The second rail 408 (top) is attached to the second end 114 of the center panel 902 using an adhesive, fastener, or bonding process. Several examples of interfaces between stiles 402, 404, rails 406, 408 and fire resistant center panel 902 are shown in fig. 3A-3D. It is noted that the central panel 902 is not suitable for forming a fire rated door alone. Fire resistant material or panels must be installed on the top 106 and bottom (not shown) of the center panel 902 to form a fire rated door. For example, if the panels 1102, 1302 are made of fire resistant material (e.g., a second fire resistant material, etc.), respectively, then the center panel 902 can be used in the doors 1100 (fig. 11A), 1200 (fig. 12A), and 1300 (fig. 13A).

Referring now to figure 10A, an exploded perspective view of a door core 1000 for a fire rated door in accordance with another embodiment of the present invention is shown. The core 1000 includes a fire resistant center panel 102 or 1002 disposed between a top insulation panel 902a and a bottom insulation panel 902b and an extruded fire resistant border 104 surrounding the three panels 902a, 102 (or 1002) and 902 b. The fire resistant center panel 102 is made of a first fire resistant material that is either castable or extrudable. The fire resistant center panel 1002 is made of a second fire resistant material that is either castable or extrudable. Top insulation panel 902a and bottom insulation panel 902b are made of a corrugated filler (e.g., cardboard, etc.) having a plurality of voids (e.g., honeycomb, hexagon, triangle, etc.) and may be filled with an acoustic insulating material (e.g., fiberglass, foam, etc.). The three plates 902a, 102 (or 1002) and 902b are typically bonded together. The fire resistant center panel 102 or 1002 has a bottom (not shown), a top 106, a first side 108, a second side 110, a first end 112, and a second end 114. Extruded fire resistant bezel 104 is comprised of a first stile 402 (left), a second stile 404 (right), a first rail 406 (top), and a second rail 408 (bottom). First stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are made of a second refractory material having a higher density than the first refractory material so that the second refractory material has holding capacity (e.g., fasteners will attach to the second refractory material and remain fixed after installation) and can be formed using an extrusion process. The first stile 402 (left), second stile 404 (right), first rail 406 (top), and second rail 408 (bottom) are bonded or fastened together and to the three plates 902a, 102 (or 1002), and 902 b. The first stile 402 (left side) is attached to the first side 108 of the three panels 902a, 102 (or 1002), and 902b using an adhesive, fastener, or bonding process. The second stile 404 (right side) is attached to the second side 110 of the three panels 902a, 102 (or 1002), and 902b using an adhesive, fastener, or bonding process. The first rail 406 (top) is attached to the first ends 112 of the three plates 902a, 102 (or 1002) and 902b using an adhesive, fastener or bonding process. The second rail 408 (top) is attached to the second ends 114 of the three plates 902a, 102 (or 1002), and 902b using an adhesive, fastener, or bonding process. Several examples of the interfaces between the stiles 402, 404, rails 406, 408 and the fire resistant center panel 102 are shown in fig. 3A-3D. FIG. 10B is a cross-sectional view of the door core of FIG. 10A.

It is noted that the core shown in fig. 1-10 and described above may also include a top plate attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, or a bottom plate attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, or both a top plate and a bottom plate attached to the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. An example of such a configuration is shown in fig. 13A and 14A. The top plate or the bottom plate may be a wood fiber substrate, wood composite, medium density fiberboard, high density fiberboard, particle board, insulation fiberboard (masonite), fiberglass, metal, plastic, fire resistant board, one or more protective layers, or a combination thereof. The one or more protective layers may be a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a damping material, a grounding material, an insulating material, or combinations thereof. For example, the one or more protective layers may be one or more gypsum boards, one or more metal plates, one or more lead plates, one or more Kevlar (Kevlar) plates, one or more ceramic plates, a layer of polyurethane foam, a layer of graphite, a wire mesh, or combinations thereof. Further, the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, and/or the top or bottom plate may be coated with an intumescent or refractory material.

Referring now to figure 11A, an exploded perspective view of a fire rated door 1100 in accordance with one embodiment of the present invention is shown. The fire rated door 1100 includes a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 (see figures 1-10 and related description for details), a first decorative panel 1102, and a second decorative panel 1104. The first decorative panel 1102 and the second decorative panel 1104 may be wood fiber based panels, wood composites, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, fire resistant materials, or combinations thereof. A first decorative panel 1102 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with adhesive. A second decorative panel 1104 is attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with an adhesive. It is noted that the binder may have fire resistant properties or contain intumescent materials. The first and second decorative panels 1102, 1104 have slightly greater lengths and widths to accommodate the wrap strips 1106 attached to each side and each end of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. The outer wrap strips 1106 may have a first wrap strip 1106a, a second wrap strip 1106b, a third wrap strip 1106c, and a fourth wrap strip 1106 d. Figure 11B illustrates a cross-sectional view of the fire rated door 1100. Figure 11C illustrates a cross-sectional view of an alternative form of the fire rated door 1100 in which an intumescent strip material 1108 may also be disposed between the outer wrap strip 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000.

Referring now to figure 12A, an exploded perspective view of a fire rated door 1200 in accordance with another embodiment of the present invention is shown. The fire rated door 1200 includes a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 (see figures 1-10 and related description for details), a first decorative panel 1102, and a second decorative panel 1104. The first decorative panel 1102 and the second decorative panel 1104 may be wood fiber based panels, wood composites, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, fire resistant materials, or combinations thereof. It is to be noted that the first decorative panel 1102 and the second decorative panel 1104 may also have fire resistant properties. A first decorative panel 1102 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with adhesive. A second decorative panel 1104 is attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with an adhesive. It is noted that the binder may have fire resistant properties or contain intumescent materials. The first decorative panel 1102 and the second decorative panel 1104 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. No additional wrap strips, rails and stiles are required. Figure 12B illustrates a cross-sectional view of the fire rated door 1200.

Referring now to figure 13A, an exploded perspective view of a fire rated door 1300 in accordance with another embodiment of the present invention is shown. The fire rated door 1300 includes a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 (see figures 1-10 and related description for details), a first protective panel or layer 1302 (also referred to as a top panel), a first decorative panel 1102, a second protective panel or layer 1304 (also referred to as a bottom panel), and a second decorative panel 1104. The first protective sheet or layer 1302 and the second protective sheet or layer 1304 can be a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation protective material, a damping material, a grounding material, an insulating material, or a combination thereof. For example, the first protective sheet or layer 1302 and the second protective sheet or layer 1304 can be one or more gypsum boards, one or more metal boards, one or more lead boards, one or more Kevlar (Kevlar) boards, one or more ceramic boards, a layer of polyurethane foam, a layer of graphite, a wire mesh, or a combination thereof. A 120 minute class fire rated door may be obtained by using a dense refractory material, such as a StarStone material, for the first protective sheet or layer 1302 and the second protective sheet or layer 1304. The first decorative panel 1102 and the second decorative panel 1104 may be wood fiber based panels, wood composites, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, fire resistant materials, or combinations thereof. A first decorative panel 1102 is attached to the top of the first protective sheet or layer 1302 with an adhesive. The first protective sheet or layer 1302 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with an adhesive. A second decorative panel 1104 is attached to the bottom of the second protective panel or layer 1304 using an adhesive. The second protective sheet or layer 1304 is attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 using an adhesive. It is noted that the binder may have fire resistant properties or contain intumescent materials. The first decorative panel 1102, the second decorative panel 1104, the first protective panel or layer 1302, and the second protective panel or layer 1304 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000. No additional wrap strips, rails and stiles are required. Figure 13B illustrates a cross-sectional view of the fire rated door 1300. Figure 13C shows a cross-sectional view of an alternative form of the fire rated door 1300 in which the first and second decorative panels 1102, 1104 have slightly greater lengths and widths to accommodate the wrap strips 1106 attached to each side and each end of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. As shown in fig. 11A, the outsourcing strips 1106 may include a first strip 1106a, a second strip 1106b, a third strip 1106c and a fourth strip 1106 d. Further, the alternative form of the fire rated door 1300 may be manufactured with an intumescent strip material 1108 disposed between the outer wrap strip 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (see figure 11C).

Referring now to figure 14A, an exploded perspective view of a fire rated door 1400 in accordance with another embodiment of the present invention is shown. The fire rated door 1400 includes a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 (see figures 1-10 and related description for details), a first insulating panel or layer 1402, a first decorative panel 1102, a second insulating panel or layer 1404, and a second decorative panel 1104. The first insulating panel or layer 1402 and the second protective panel or layer 1404 are made of a corrugated filler (e.g., cardboard, etc.) having a plurality of voids (e.g., honeycomb, hexagon, triangle, etc.) filled with an insulating and/or fire-resistant material (e.g., fiberglass, foam, etc.). The first decorative panel 1102 and the second decorative panel 1104 may be wood fiber based panels, wood composites, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, fire resistant materials, or combinations thereof. A first decorative panel 1102 is attached to the top of the first insulating panel or layer 1402 with an adhesive. The first insulating panel or layer 1402 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with an adhesive. The second decorative panel 1104 is attached to the bottom of the second insulating panel or layer 1404 using an adhesive. The second insulating panel or layer 1404 is attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 with an adhesive. It is noted that the binder may have fire resistant properties or contain intumescent materials. The first decorative panel 1102, the second decorative panel 1104, the first insulating panel or layer 1402, and the second insulating panel or layer 1404 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000. No additional wrap strips, rails and stiles are required. Figure 14B illustrates a cross-sectional view of the fire rated door 1400. Figure 14C shows a cross-sectional view of an alternative form of the fire rated door 1400 in which the first and second decorative panels 1102, 1104 have slightly greater lengths and widths to accommodate the wrap strips 1106 attached to each side and each end of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. As shown in fig. 11A, the outsourcing strips 1106 may include a first strip 1106a, a second strip 1106b, a third strip 1106c and a fourth strip 1106 d. In addition, an alternative form of the fire rated door 1400 may be manufactured with an intumescent strip material 1108 disposed between the outer wrap strip 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 (see figure 11C).

Referring now to figure 15A, an exploded perspective view of a fire rated door 1500 in accordance with another embodiment of the present invention is shown. The fire rated door 1500 includes a core 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 (see figures 1-10 and related description for details), a first trim panel 1102, a second trim panel 1104, and four bars 1502. Alternatively, the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 may be a single piece of refractory material including, but not limited to, a first refractory material. The back sides of the first and second trim panels 1102, 1104 include notches or cutouts 1504 along the left and right sides sized to mount the respective bars 1502. Each bar 1502 is made of the second refractory material or other suitable material. In one embodiment, the bar has a height of 11/16 "and a width of 1". The first decorative panel 1102 and the second decorative panel 1104 may be wood fiber based panels, wood composites, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, fire resistant materials, or combinations thereof. It is to be noted that the first decorative panel 1102 and the second decorative panel 1104 may also have fire resistant properties. A first decorative panel 1102 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or the top of the single piece of refractory material with an adhesive. A second decorative panel 1104 is attached to the bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or the bottom of the single piece of refractory material with an adhesive. It is noted that the binder may have fire resistant properties or contain intumescent materials. The first and second decorative panels 1102, 1104 have the same length and width as the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or a single piece of fire resistant material. No additional wrap strips, rails and stiles are required. Figure 15B illustrates a cross-sectional view of the fire rated door 1400.

Referring now to figure 16, a flow diagram of a method 1600 of manufacturing a door core for a fire rated door in accordance with one embodiment of the present invention is shown. A fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end is provided in block 1602, wherein the fire resistant center panel is made of a first fire resistant material. In block 1604, a first stile of an extruded fire resistant border is attached to the first side of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material. In block 1606, a second stile of the extruded fire resistant border is attached to the second side of the fire resistant center panel. In block 1608, a first rung of the extruded fire resistant border is attached to the first end of the fire resistant center panel and the first and second stiles of the extruded fire resistant border. In block 1610, a second rung of the extruded fire resistant border is attached to the second end of the fire resistant center panel and the first and second stiles of the extruded fire resistant border. In block 1612, an optional step includes forming the fire rated door by attaching first and second fascia panels to top and bottom portions of the first stile, the second stile, the first rail, and the second rail of the fire resistant center panel and the extruded fire resistant border, respectively. Additional elements may be added as described with respect to fig. 11-15. Another optional step includes coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material. It is noted that method 1600 may be implemented as part of a continuous manufacturing process.

In one embodiment, a notch is formed in the first side of the fire resistant center panel, the notch having a fire resistant lock seat embedded therein, the fire resistant lock seat attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock seat is made of the second fire resistant material. In another embodiment, the fire resistant center panel comprises: (a) a first fire resistant center panel disposed between the first side and the second side adjacent the first end, wherein the first fire resistant center panel is made from the first fire resistant material; (b) a second fire resistant center panel disposed between the first side and the second side adjacent the second end, wherein the second fire resistant center panel is made from the first fire resistant material; and (c) a fire resistant insert disposed between and attached to the first fire resistant center panel and the second fire resistant center panel and extending between and attached to the extruded fire resistant border at the first side and the second side, wherein the fire resistant material is made from the second fire resistant material. In yet another embodiment, a set of male and female connectors are formed in the extruded fire resistant border and the fire resistant center panel. The male and female connectors may be triangular, curved, rectangular, angled, tongue-and-groove, or combinations thereof.

In another embodiment, a first fire resistant material is extruded or molded to form the fire resistant center panel and a second fire resistant material is extruded or molded to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border. In yet another embodiment, a first fire resistant material is extruded or molded to form the fire resistant center panel and a second fire resistant material is extruded or molded to form a sheet material that is subsequently sawn with a gang saw to form one or more of the first stile, the second stile, the first rail, and the second rail of the extruded fire resistant border. In either embodiment, the panels, stiles and rails may be subjected to one or more finishing steps (e.g., sanding, edging, cutting, sanding, etc.) to provide the proper smoothness, size and shape to these components.

Further, a top plate may be attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom plate may be attached to the bottom of the fire resistant center panel, or both a top plate and a bottom plate may be attached to the fire resistant center panel. The top panel or the bottom panel may be a wood fiber substrate, wood composite, medium density fiberboard, high density fiberboard, particle board, insulated fiber board, fiberglass, metal, plastic, one or more protective layers, or a combination thereof. The one or more protective layers may be a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a damping material, a grounding material, an insulating material, or combinations thereof. For example, the one or more protective layers may be one or more gypsum boards, one or more metal plates, one or more lead plates, one or more Kevlar (Kevlar) plates, one or more ceramic plates, a layer of polyurethane foam, a layer of graphite, a wire mesh, or combinations thereof.

Referring now to figure 17, a flow diagram of a method 1700 of manufacturing a door core for a fire rated door in accordance with another embodiment of the present invention is shown. In block 1702, an extruded fire resistant bezel is provided. The extruded fire resistant jamb has a central void and is manufactured by providing a first stile of the extruded fire resistant jamb, attaching a first rail of the extruded fire resistant jamb to the first stile of the extruded fire resistant jamb, attaching a second rail of the extruded fire resistant jamb to the first stile, and attaching the second stile of the extruded fire resistant jamb to the first rail and the second rail of the extruded fire resistant jamb, wherein the extruded fire resistant jamb is made of a second fire resistant material. In block 1704, the void within the extruded fire resistant border is filled with a first fire resistant material having a lower density than a second fire resistant material to form a fire resistant center panel. In block 1706, the extruded fire resistant border and the first fire resistant material are baked or cured to set and fix the materials. Sanding or other finishing steps may be performed thereafter. In block 1708, an optional step includes forming a fire rated door by attaching a first trim panel and a second trim panel to the top and bottom of the extruded fire resistant border and the fire resistant center panel, respectively. Additional elements may be added as described with respect to fig. 11-15. Another optional step includes coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material. It is noted that method 1700 may be implemented as part of a continuous manufacturing process.

In another embodiment, a first fire resistant material is extruded or molded to form the fire resistant center panel and a second fire resistant material is extruded or molded to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border. In yet another embodiment, a first fire resistant material is extruded or molded to form the fire resistant center panel and a second fire resistant material is extruded or molded to form a sheet material that is subsequently sawn with a gang saw to form one or more of the first stile, the second stile, the first rail, and the second rail of the extruded fire resistant border.

Referring now to figure 18, a flow diagram of a method 1800 of manufacturing a fire rated door in accordance with one embodiment of the present invention is shown. In block 1802, a door core as shown in fig. 1-10 is provided. A first decorative panel is attached to the top of the door core in block 1804 and a second decorative panel is attached to the bottom of the door core in block 1806. Additional elements may be added as described with respect to fig. 11-14.

Claims

1. A fire rated door, comprising:

a core, comprising: (a) a gypsum-based fire resistant center panel having a bottom, a top, a first side, a second side, a first end, and a second end, wherein the gypsum-based fire resistant center panel is made from a first gypsum-based fire resistant material, and (b) an extruded gypsum-based fire resistant border attached to the first side, the second side, the first end, and the second end of the gypsum-based fire resistant center panel, wherein the extruded gypsum-based fire resistant border is made from a second gypsum-based fire resistant material having a higher density than the first gypsum-based fire resistant material, and the first gypsum-based fire resistant material and the second gypsum-based fire resistant material are comprised of water, gypsum, a cellulosic material or fibrous material, glass, a ceramic material, and one or more binders;

a first trim panel attached to a top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border; and

a second trim panel attached to a bottom of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border.

2. The fire rated door as recited in claim 1, further comprising:

a notch in the first side of the gypsum based fire resistant center panel; and

a gypsum-based fire resistant lock seat disposed within the gap and attached to the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border, wherein the gypsum-based fire resistant lock seat is made from the second gypsum-based fire resistant material.

3. The fire rated door as recited in claim 1, wherein the gypsum based fire resistant center panel comprises:

a first gypsum based fire resistant center panel disposed between the first side and the second side proximate the first end, wherein the first gypsum based fire resistant center panel is made from the first gypsum based fire resistant material;

a second gypsum based fire resistant center panel disposed between the first side and the second side proximate the second end, wherein the second gypsum based fire resistant center panel is made from the first gypsum based fire resistant material; and

a gypsum-based fire resistant insert disposed between and attached to the first and second gypsum-based fire resistant central panels and extending between and attached to the extruded gypsum-based fire resistant border at the first and second sides, wherein the gypsum-based fire resistant insert is made from the second gypsum-based fire resistant material.

4. The fire rated door as recited in claim 1, wherein the extruded gypsum based fire resistant border is attached to the gypsum based fire resistant center panel by way of a set of male and female joints formed in the extruded gypsum based fire resistant border and the gypsum based fire resistant center panel.

5. The fire rated door as recited in claim 4, wherein the male-female joints are triangular, curvilinear, rectangular, tongue-and-groove, or combinations thereof.

6. The fire rated door as recited in claim 4, wherein the male and female connectors are angled.

7. The fire rated door as recited in claim 1, wherein the first and second gypsum-based refractory materials are extruded or molded.

8. The fire rated door as recited in claim 1, wherein the extruded gypsum based fire resistant border is assembled, the gypsum based fire resistant center panel being cast and congealed within the extruded gypsum based fire resistant border.

9. The fire rated door as recited in claim 1, wherein the extruded gypsum-based fire resistant border comprises:

a first stile;

a second stile;

a first rail attached to the first stile and the second stile; and

a second rail attached to the first stile and the second stile.

10. The fire rated door as recited in claim 1, further comprising a top panel attached to a top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border, or a bottom panel attached to the bottom of the gypsum-based fire resistant center panel, or both the top panel and the bottom panel.

11. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises a lignocellulosic substrate, wood, metal, plastic, one or more protective layers, or a combination thereof.

12. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises a wood composite material.

13. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises a medium density fiberboard.

14. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises a high density fiberboard.

15. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises particle board.

16. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises an insulated fiber panel.

17. The fire rated door as recited in claim 10, wherein the top panel or the bottom panel comprises fiberglass.

18. The fire rated door as recited in claim 11, wherein the one or more protective layers comprise a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation protective material, a damping material, a grounding material, an insulating material, or combinations thereof.

19. The fire rated door as recited in claim 11, wherein the one or more protective layers comprise one or more gypsum boards, one or more metal sheets, one or more lead sheets, one or more kevlar sheets, one or more ceramic sheets, layers of polyurethane foam, layers of graphite, wire mesh, or combinations thereof.

20. The fire rated door as recited in claim 1, wherein the gypsum based fire resistant center panel and the extruded gypsum based fire resistant border are coated with an intumescent or fire resistant material.

21. The fire rated door as recited in claim 1, further comprising an exterior wrap strip attached to each side and each end of the extruded gypsum-based fire resistant border.

22. The fire rated door as recited in claim 21, further comprising an intumescent strip material disposed between the exterior wrap strip and the extruded gypsum-based fire resistant border.

23. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise a lignocellulosic substrate, wood, metal, plastic, or combinations thereof.

24. The fire rated door as recited in claim 1, wherein the first and second trim panels comprise a wood composite material.

25. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise medium density fiberboard.

26. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise high density fiberboard.

27. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise particle board.

28. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise insulated fiberboard.

29. The fire rated door as recited in claim 1, wherein the first and second decorative panels comprise fiberglass.

30. The fire rated door as recited in claim 1, wherein the gypsum based fire resistant center panel comprises:

a middle plate made of the first gypsum-based refractory material or the second gypsum-based refractory material;

a top insulated panel attached to the top of the middle panel; and

a bottom insulation plate attached to a bottom of the middle plate.

31. The fire rated door as recited in claim 30, wherein the top insulating panel and the bottom insulating panel are each made of a corrugated filler having a plurality of voids filled with an acoustic insulating material.

32. A method of manufacturing a fire rated door comprising the steps of:

providing a core comprising the steps of:

providing a gypsum based fire resistant center panel having a bottom, a top, a first side, a second side, a first end, and a second end, wherein the gypsum based fire resistant center panel is made from a first gypsum based fire resistant material,

attaching a first stile of an extruded gypsum-based fire resistant border to a first side of the gypsum-based fire resistant center panel, wherein the extruded gypsum-based fire resistant border is made of a second gypsum-based fire resistant material having a higher density than the first gypsum-based fire resistant material, and the first and second gypsum-based fire resistant materials are comprised of water, gypsum, a cellulosic or fibrous material, glass, a ceramic material, and one or more binders,

attaching a second stile of the extruded gypsum-based fire resistant border to a second side of the gypsum-based fire resistant center panel;

attaching a first rail of the extruded gypsum-based fire resistant border to a first end of the gypsum-based fire resistant center panel and to the first and second stiles of the extruded gypsum-based fire resistant border, and

attaching a second rail of the extruded gypsum-based fire resistant border to a second end of the gypsum-based fire resistant center panel and to the first and second stiles of the extruded gypsum-based fire resistant border;

attaching a first decorative panel to the top of the core; and

a second trim panel is attached to the bottom of the core.

33. The method of claim 32, further comprising the steps of:

forming a notch in a first side of the gypsum-based fire resistant center panel; and

inserting a gypsum-based fire resistant lock seat into the notch and attaching the gypsum-based fire resistant lock seat to the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border, wherein the gypsum-based fire resistant lock seat is made from a second gypsum-based fire resistant material.

34. The method of claim 32, wherein the gypsum-based fire resistant center panel comprises:

a gypsum-based fire resistant insert disposed between and attached to the first and second gypsum-based fire resistant central panels and extending between and attached to the extruded gypsum-based fire resistant border at the first and second sides, wherein the gypsum-based fire resistant insert is made from a second gypsum-based fire resistant material.

35. The method of claim 32, further comprising the steps of: forming a set of male and female joints in the extruded gypsum-based fire resistant border and the gypsum-based fire resistant center panel.

36. The method of claim 35, wherein the male-female joint is triangular, curvilinear, rectangular, tongue-and-groove, or a combination thereof.

37. The method of claim 35, wherein the male and female connectors are angled.

38. The method of claim 32, further comprising the steps of:

extruding or molding the first gypsum-based fire resistant material to form the gypsum-based fire resistant center panel; and

extruding or molding the second gypsum-based refractory material to form a first stile, a second stile, a first rail, and a second rail of the extruded gypsum-based refractory jamb.

39. The method of claim 32, further comprising the steps of:

extruding or molding the second gypsum-based refractory material to form a sheet, and sawing the sheet with a gang saw to form one or more of a first stile, a second stile, a first rail, or a second rail of the extruded gypsum-based refractory jamb.

40. The method of claim 32, further comprising the steps of: attaching a top plate to the top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border, or attaching a bottom plate to the bottom of the gypsum-based fire resistant center panel, or attaching both the top plate and the bottom plate.

41. The method of claim 40, wherein the top sheet or the bottom sheet comprises a lignocellulosic substrate, wood, metal, plastic, one or more protective layers, or a combination thereof.

42. The method of claim 40, wherein the top plate or the bottom plate comprises a wood composite material.

43. The method of claim 40, wherein the top plate or the bottom plate comprises medium density fiberboard.

44. The method of claim 40, wherein the top plate or the bottom plate comprises high density fiberboard.

45. The method of claim 40, wherein the top plate or the bottom plate comprises particle board.

46. The method of claim 40, wherein the top plate or the bottom plate comprises an insulated fiber board.

47. The method of claim 40, wherein the top plate or the bottom plate comprises fiberglass.

48. The method of claim 41, wherein the one or more protective layers comprise a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a damping material, a grounding material, an insulating material, or a combination thereof.

49. The method of claim 41, wherein the one or more protective layers comprise one or more gypsum boards, one or more metal plates, one or more lead plates, one or more Kevlar plates, one or more ceramic plates, polyurethane foam layers, graphite layers, wire mesh, or combinations thereof.

50. The method of claim 32, further comprising the steps of: coating the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border with an intumescent or fire resistant material.

51. The method of claim 32, wherein the method is performed as part of a continuous manufacturing process.

52. The method of claim 32, further comprising the steps of: a fire rated door is formed by attaching a first decorative panel to the top of the core and a second decorative panel to the bottom of the core.

53. The method of claim 32, wherein the gypsum-based fire resistant center panel comprises:

a top insulated panel attached to the top of the middle panel; and

a bottom insulation plate attached to a bottom of the middle plate.

54. The method of claim 53, wherein the top and bottom insulation panels are made of corrugated filler having a plurality of voids filled with an acoustic insulation material.

55. A method of manufacturing a fire rated door comprising the steps of:

providing a core comprising the steps of:

providing an extruded gypsum-based refractory frame having a void in the middle by providing a first stile of the extruded gypsum-based refractory frame, attaching a first rail of the extruded gypsum-based refractory frame to the first stile of the extruded gypsum-based refractory frame, attaching a second rail of the extruded gypsum-based refractory frame to the first stile, and attaching a second stile of the extruded gypsum-based refractory frame to the first and second rails of the extruded gypsum-based refractory frame, wherein the extruded gypsum-based refractory frame is made of a second gypsum-based refractory material, and the first and second gypsum-based refractory materials are comprised of water, gypsum, cellulosic or fibrous materials, glass, ceramic materials, and one or more binders,

filling the void within the extruded gypsum-based fire resistant border with a first gypsum-based fire resistant material having a lower density than the second gypsum-based fire resistant material to form a gypsum-based fire resistant center panel; and

baking the extruded gypsum-based refractory border and the first gypsum-based refractory material;

attaching a first decorative panel to the top of the core; and

a second trim panel is attached to the bottom of the core.

56. The method of claim 55, further comprising the steps of: embedding a gypsum-based refractory lock seat within the extruded gypsum-based refractory border, wherein the gypsum-based refractory lock seat is made from the second gypsum-based refractory material.

57. The method of claim 55, wherein the gypsum-based fire resistant center panel comprises:

a gypsum-based fire resistant insert disposed between and attached to the first and second gypsum-based fire resistant central panels and extending between and attached to the extruded gypsum-based fire resistant border at the first and second sides, wherein the gypsum-based fire resistant material is made from the second gypsum-based fire resistant material.

58. The method of claim 55, further comprising the steps of: forming a set of male and female joints in the extruded gypsum-based fire resistant border and the gypsum-based fire resistant center panel.

59. The method of claim 58, wherein the male-female joint is triangular, curvilinear, rectangular, tongue-and-groove, or a combination thereof.

60. The method of claim 58, wherein the male-female joint is angular.

61. The method of claim 55, further comprising the steps of:

62. The method of claim 55, further comprising the steps of:

63. The method of claim 55, further comprising the steps of: attaching a top plate to the top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border, or attaching a bottom plate to the bottom of the gypsum-based fire resistant center panel, or attaching both the top plate and the bottom plate.

64. The method of claim 59, wherein the top or bottom sheet comprises a lignocellulosic substrate, wood, metal, plastic, one or more protective layers, or a combination thereof.

65. The method of claim 59, wherein the top plate or the bottom plate comprises a wood composite material.

66. The method of claim 59, wherein said top plate or said bottom plate comprises medium density fiberboard.

67. The method of claim 59, wherein said top plate or said bottom plate comprises high density fiberboard.

68. The method of claim 59, wherein said top plate or said bottom plate comprises particle board.

69. The method of claim 59, wherein said top plate or said bottom plate comprises an insulated fiber board.

70. The method of claim 59, wherein said top plate or said bottom plate comprises fiberglass.

71. The method of claim 64, wherein the one or more protective layers comprise a fire resistant material, an explosion proof material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a damping material, a grounding material, an insulating material, or a combination thereof.

72. The method of claim 71, wherein the one or more protective layers comprise one or more gypsum boards, one or more metal plates, one or more lead plates, one or more Kevlar plates, one or more ceramic plates, polyurethane foam layers, graphite layers, wire mesh, or combinations thereof.

73. The method of claim 71, further comprising the steps of: coating the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border with an intumescent or fire resistant material.

74. The method of claim 55, wherein the method is performed as part of a continuous manufacturing process.

75. The method of claim 55, further comprising the steps of: a fire rated door is formed by attaching a first decorative panel to the top of the core and a second decorative panel to the bottom of the core.

76. The method of claim 55, wherein the gypsum-based fire resistant center panel comprises:

a top insulated panel attached to the top of the middle panel; and

a bottom insulation plate attached to a bottom of the middle plate.

77. The method of claim 76, wherein the top insulation panel and the bottom insulation panel are each made of a corrugated filler having a plurality of voids filled with an acoustic insulation material.