Patent ID: 8209866
Filing Date: 2012-07-03
Classification: E06B,Y10T

Abstract:
1. A method for manufacturing a fire rated door comprising the steps of: providing a first door-sized panel having two longitudinal interior channels cut into a back side of the first door-sized panel, and a second door-sized panel having two longitudinal interior channels cut into a back side of a second door-sized panel; assembling a door slab by (a) inserting a spline in each longitudinal interior channel of the first door-sized panel, (b) attaching the back side of the second door-sized panel directly to (i) the splines inserted in the first door-sized panel such that the splines are also inserted into the longitudinal interior channels of the second door-sized panel and (ii) the back of the first door-sized panel using an adhesive, and (c) applying pressure to the door slab to bond the splines and the door-sized panels together; cutting a perimeter channel in each side of the door slab; inserting (a) an intumescent banding material in each perimeter channel, and (b) an exterior banding in each perimeter channel to conceal the intumescent banding material within the perimeter channel; and wherein the fire rating for the door is achieved without a mineral core disposed between the first door-sized panel and the second door sized panel by (a) the intumescent banding material and (b) one or more of the following: (i) the adhesive is fire resistant, (ii) the first door-sized panel and the second door-sized panel contain an intumescent or fire resistant material, or (iii) the first door-sized panel and the second door-sized panel are coated with the intumescent or fire resistant material.