Fire rated door core
First Claim
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1. A method of manufacturing a fire rated door, comprising:
- extruding a first fire resistant material to form a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end;
extruding a second fire resistant material to form a first stile, a second stile, a first rail and a second rail of an extruded fire resistant border;
wherein the second fire resistant material has a higher density than the first fire resistant material, and the first fire resistant material and the second fire resistant material are composed of water, gypsum to provide fire resistance, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents;
attaching the first stile of the extruded fire resistant border to the first side of the fire resistant center panel;
attaching the second stile of the extruded fire resistant border to the second side of the fire resistant center panel;
attaching the first rail of the extruded fire resistant border to the first end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border; and
attaching the second rail of the extruded fire resistant border to the second end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border;
attaching top panel to the top of the fire resistant center panel, wherein the top panel extends to an outer edge of the first stile, the second stile, the first rail and the second rail;
attaching a bottom panel to the bottom of the fire resistant center panel, wherein the bottom panel extends to the outer edge of the first stile, the second stile, the first rail and the second rail;
attaching a first decorative panel to a top of the top panel, wherein the first decorative panel extends at least to an outer edge of the top panel; and
attaching a second decorative panel to a bottom of the top panel, wherein the second decorative panel extends at least to an outer edge of the bottom panel.
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Abstract
A core for a fire rated door includes a fire resistant center panel and an 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 of a first fire resistant material. The extruded fire resistant border is attached to the first side, the second side, the first end and the second end of the fire resistant center panel. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.
311 Citations
13 Claims
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1. A method of manufacturing a fire rated door, comprising:
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extruding a first fire resistant material to form a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end; extruding a second fire resistant material to form a first stile, a second stile, a first rail and a second rail of an extruded fire resistant border; wherein the second fire resistant material has a higher density than the first fire resistant material, and the first fire resistant material and the second fire resistant material are composed of water, gypsum to provide fire resistance, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents; attaching the first stile of the extruded fire resistant border to the first side of the fire resistant center panel; attaching the second stile of the extruded fire resistant border to the second side of the fire resistant center panel; attaching the first rail of the extruded fire resistant border to the first end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border; and attaching the second rail of the extruded fire resistant border to the second end of the fire resistant center panel and the first stile and the second stile of the extruded fire resistant border; attaching top panel to the top of the fire resistant center panel, wherein the top panel extends to an outer edge of the first stile, the second stile, the first rail and the second rail; attaching a bottom panel to the bottom of the fire resistant center panel, wherein the bottom panel extends to the outer edge of the first stile, the second stile, the first rail and the second rail; attaching a first decorative panel to a top of the top panel, wherein the first decorative panel extends at least to an outer edge of the top panel; and attaching a second decorative panel to a bottom of the top panel, wherein the second decorative panel extends at least to an outer edge of the bottom panel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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Specification