FIRE RATED DOOR CORE

1 . A core for a fire rated door comprising:

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 of a first fire resistant material; and

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 of a second fire resistant material having a higher density than the first fire resistant material.

2 . The core as recited in claim 1 , further comprising:

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

a fire resistant lock block disposed within the notch and attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.

3 . The core as recited in claim 1 , wherein the fire resistant center panel comprises:

a first fire resistant panel made of the first fire resistant material;

a second fire resistant panel made of the first fire resistant material; and

an extruded 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 of the second fire resistant material.

4 . The core as recited in claim 1 , wherein the extruded fire resistant border is attached to the fire resistant center panel with a set of male-female connectors formed in the extruded fire resistant border and the fire resistant center panel.

5 . The core as recited in claim 4 , wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.

6 . The core as recited in claim 1 , wherein the first fire resistant material is extruded or molded.

7 . The core as recited in claim 1 , wherein the extruded fire resistant border is assembled and the fire resistant center panel is poured and set within the extruded fire resistant border.

8 . The core as recited in claim 1 , wherein the extruded 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.

9 . The core as recited in claim 1 , further comprising a top panel attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom panel attached to the bottom of the fire resistant center panel, or both the top panel and the bottom panel.

10 . The core as recited in claim 10 , wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.

11 . The core as recited in claim 11 , wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.

12 . The core as recited in claim 11 , wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.

13 . The core as recited in claim 1 , wherein the fire resistant center panel and the extruded fire resistant border are coated with an intumescent or fire resistant material.

14 . The core as recited in claim 1 , wherein the first fire resistant material and the second fire resistant material are composed of water, gypsum, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents.

15 . The core as recited in claim 1 , wherein the fire resistant center panel comprises:

a center panel made of the first fire resistant material or the second fire resistant material;

a top insulating panel attached to the top of the center panel; and

a bottom insulating panel attached to the bottom of the center panel.

16 . The core as recited in claim 15 , wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.

17 . A method of manufacturing a core for a fire rated door, comprising the steps of:

providing 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 of a first fire resistant material;

attaching a first stile of an extruded fire resistant border 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;

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

attaching a 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 a 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.

18 . The method as recited in claim 17 , further comprising the steps of:

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

inserting a fire resistant lock block within the notch and attaching the fire resistant lock block to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.

19 . The method as recited in claim 17 , wherein the fire resistant center panel comprises:

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

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

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 of the second fire resistant material.

20 . The method as recited in claim 17 , further comprising the step of forming a set of male-female connectors in the extruded fire resistant border and the fire resistant center panel.

21 . The method as recited in claim 20 , wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.

22 . The method as recited in claim 17 , further comprising the steps of:

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

extruding or molding the second fire resistant material to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border.

23 . The method as recited in claim 17 , further comprising the steps of:

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

extruding or molding the second fire resistant material to form a sheet, and gang ripping the sheet to form one or more of the first stile, the second stile, the first rail or the second rail of the extruded fire resistant border.

24 . The method as recited in claim 17 , further comprising the step of attaching a top panel to the top of the fire resistant center panel and the extruded fire resistant border, or attaching a bottom panel to the bottom of the fire resistant center panel, or attaching both the top panel and the bottom panel.

25 . The method as recited in claim 24 , wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.

26 . The method as recited in claim 25 , wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.

27 . The method as recited in claim 25 , wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.

28 . The method as recited in claim 17 , further comprising the step of coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material.

29 . The method as recited in claim 17 , wherein the method is performed as part of a continuous manufacturing process.

30 . The method as recited in claim 17 , further comprising the step of forming a fire rated door by attaching a first decorative panel to a top of the core and attaching a second decorative panel to a bottom of the core.

31 . The method as recited in claim 17 , wherein the fire resistant center panel comprises:

a center panel made of the first fire resistant material or the second fire resistant material;

a top insulating panel attached to the top of the center panel; and

a bottom insulating panel attached to the bottom of the center panel.

32 . The method as recited in claim 31 , wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.

33 . A method of manufacturing a core for a fire rated door, comprising the steps of:

providing an extruded fire resistant border having a central void by providing a first stile of the extruded fire resistant border, attaching a first rail of the extruded fire resistant border to the first stile of the extruded fire resistant border, attaching a second rail of the extruded fire resistant border to the first stile and attaching a second stile of the extruded fire resistant border to the first rail and the second rail of the extruded fire resistant border, wherein the extruded fire resistant border is made of a second fire resistant material;

filling the void within the extruded fire resistant border with a first fire resistant material that has a lower density than the second fire resistant material to form a fire resistant center panel; and

baking the extruded fire resistant border and first fire resistant material.

34 . The method as recited in claim 33 , further comprising the step of inserting a fire resistant lock block within the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.

35 . The method as recited in claim 33 , wherein the fire resistant center panel comprises:

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

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

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 of the second fire resistant material.

36 . The method as recited in claim 33 , further comprising the step of forming a set of male-female connectors in the extruded fire resistant border and the fire resistant center panel.

37 . The method as recited in claim 36 , wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.

38 . The method as recited in claim 33 , further comprising the steps of:

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

extruding or molding the second fire resistant material to form the first stile, the second stile, the first rail and the second rail of the extruded fire resistant border.

39 . The method as recited in claim 33 , further comprising the steps of:

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

extruding or molding the second fire resistant material to form a sheet, and gang ripping the sheet to form one or more of the first stile, the second stile, the first rail or the second rail of the extruded fire resistant border.

40 . The method as recited in claim 33 , further comprising the step of attaching a top panel to the top of the fire resistant center panel and the extruded fire resistant border, or attaching a bottom panel to the bottom of the fire resistant center panel, or attaching both the top panel and the bottom panel.

41 . The method as recited in claim 40 , wherein the top panel or the bottom panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, a particleboard, a masonite, a fiberglass, a metal, a plastic, one or more protective layers or a combination thereof.

42 . The method as recited in claim 41 , wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material, insulating material or a combination thereof.

43 . The method as recited in claim 41 , wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof.

44 . The method as recited in claim 33 , further comprising the step of coating the fire resistant center panel and the extruded fire resistant border with an intumescent or fire resistant material.

45 . The method as recited in claim 33 , wherein the method is performed as part of a continuous manufacturing process.

46 . The method as recited in claim 33 , wherein the first fire resistant material and the second fire resistant material are composed of water, gypsum, a cellulose or fiber material, glass, a ceramic material, and one or more binding agents.

47 . The method as recited in claim 33 , further comprising the step of forming a fire rated door by attaching a first decorative panel to a top of the core and attaching a second decorative panel to a bottom of the core.

48 . The method as recited in claim 33 , wherein the fire resistant center panel comprises:

a center panel made of the first fire resistant material or the second fire resistant material;

a top insulating panel attached to the top of the center panel; and

a bottom insulating panel attached to the bottom of the center panel.

49 . The method as recited in claim 48 , wherein the top insulating panel and the bottom insulating panel are made of a corrugated filler having a plurality of voids filled with an acoustical insulating material.