'US01024008952 2) United States Patent (10) Patent No: — US 10,240,089 B2 Daniels et al. (4s) Date of Patent: *Mar. 26, 2019 oy USED IN FIRE (58) Field of Classification Search ‘OMPONENTS, CBC ee COAB 2111/0062; COSB 2111/82; COA 28/14; COMB 20/0048; COSB 24/383 (71) Applicant: ‘The Intellectual Gorilla GmbH, (Contined) Entlebuek (CH) 66) References Cited (72) Inventors: Evan R. Daniels, Dallas, TX (US): Jonathan Newton, Van Alstyne, 1X ws) US. PATENT DOCUMENTS s70391 A 101896 Fox 10dk923 A I2H912 Wheeler (Continved) (3) Assiunee: ‘The Intelletual Gorilla Gmbl Sempach Station (CH (4) Notice: Subjoct to any disclaimer the term of this FOREIGN PATENT DOCUMENTS patent is extended or adjusted under 35 USC. 1846) by 0 days. This patent is subjeet to a terminal dis- claims, (Continsed) OTHER PUBLICATIONS eee eae EP 147595144 Extonlod European Seach Report dal Sep. 23, (22) Filed: Aug. 8, 2016 2016 (Continved) i) eae enna Primary Evaminer —Cazaie S Thompson 201610340587 AL Nov. 24, 2016 (74) Attorney, Agent, oF Firm — Daniel 1, Chalker; Edwin S. Flores; Chaiker Flores, LEP Related Us Data Applicat on ABSTRACT (60) Continuation of application No. 14/542,930, filed on composite product includes gypsum in an amount of 6D to Now. 17, 2014, now Pat, No. 9.410.361, which is a 9qb by weight, fibers ia an amount of 1.5 to 26% by weight (Continued) substantially homogeneously dstibuted through the com- posite, and a sheology-modifying agent in an amount of 0S "Cl {o GY by weight. The composites cased or allowed to cure c9K 2102 (2006.01) to form a cured composite, The cured composite isa fre cose 2038 (2005.01) resistant component sed in fire-rated door core, ire (Continued) rated door or a fire-rated building panel. The fire resistant rte component may inelude a building panel, 2 door panel, 2 ee CO9K 21102 2013.01); COAB 20/0048 SOX core, 2 door Fal, a door stile, a door lock block, a door (2013.01); Co4m 24/383 (2013.01), order, oF 2 door insert. (Continaed) 23 Claims, 12 Drawing Sheets — 800 FIGS. 38-30US 10,240,089 B2 Page 2 Related U.S. Application Data vision of application No. 13/610,542, fled on Sep. 11, 2012, now Pat. No. §.915,033, which ss contine uation-in-pan of application No. 13/608,405, fled on Sep. 4, 2012, now Pat. No. 9,375,899, which is a ‘continiationin-part of application No. 13/538,788, filed on Jun. 29, 2012, now abandoned, and a con: ‘inuation-in-part of application No, 13/538,828, fled ‘on Jun, 29, 2012, now Pat. No. 9,243,444, (1) Incr. cod 2000 (2006.01) EOSB 194 (2008.01) Code 2814 (2006.01), EO6B 82 (2006.01) EOSC 206 (2006.01) BOSC 2288 (2006.01) E068 16 (2006.01) E068 3/70 (2006.01), (2006.01) (2006.01) (2006.01) C048 111/00 (2008.01) Co4B 111/10 (2006.01), Coa 111728 (2006.01) (2) I CosB 28/14 2013.01); EosB 1941 (2013.01); Boa 1442 201301). OAC 2083 (201301): E04C 2/288 2013.01); 06 37015 (2013.01); E06B 74 2013.01): EO6B 377% (2013.01); E068 3778 (2013.01). B06 9822 (2013.01), E06B $16 (2013.01), B06 $7164 (2013.01); CO4B 2111/0062 (2013.01); (COMB 2111/105 (2013.01); CO4B 2111/1037 (2013.01), Co4B 2111/1036 (2013.01); COsB 2111/28 (2013.01); EO6B 2003/704 (2013.01); "E068 2003/7042 (2013.01); EO6B 2003/7049 (2013.01); £06B 2003/7051 (2013.01); YO2" 30/97 (2015.05), YIOT 428/232 (2015.01) (58) Field of Classitication Search CPC Coa 24/2625: COS 24/1383; COMB 14142: Coss 1610883; CoaB 16/0641; COB 2111/28; CO4B 20/20; COMB 24/38; COMB 2111/062; COMB 211/105: COB. 2111/1056; FO6R 5/16; FOS 2003/7042: EGR 2003/7049; EO6B 208/704; EOSE. 2003/7082; E068 3/76; EO6B 3/74; E06 3/78; BOaC 2/043; YOW 30/97; COOK 2102 USPC 106/772, 650, 711, 780, 79; 524/423, 524/35, 43, 44, 5; 52/784.11, 783.13, ‘Se application file for complete search history. 66) References Cited USS. PATENT DOCUMENTS. SSITAGE A 61970. Woods Sisson A 1974 Vang A (91078. Rabens A 101976 ashe A U1976 Ropela A “1977 Yamamoto 4045937 § 91977 Steck So7s804 21978 Zimmerman MowST A 41078 MeFurland 41593302 861979. Greve eta 471985 Stems? Shoo.s8s S108 Eases She0's66 S232496 Sai Shans Sas0s78 Share S3568 Sheers S376520, S385 764 S9s.571 Shor sas Sarno 5433.10 Sas, Sasn310 S40851 SSosoe? S006 Ssoso72 SSia0 Ss2nos Serer Ss0.005 Seas Ssaso7 S540 Esso Sss780 Ss@8t4 550670 S088 564307 pore S295 56631052 wos ‘91980 S98 xi981 vise Disa F198 e190 19 x19 oes 198 aioe Motoki Hodson Hodson Martin Hodson Walle Muyssto Malle Greve tal Mastin Hodson Johnson et Rivkin Shechter ackamick Hodson Wapner Wilson ea Fowler tal Tener Hagemeyer Dickson Passov el. Taher a Thom Hodson hone Thom Hodson Halo Mardiane Hedson Woodwand Seanings etal ages ae Stucky eta Seanings otal ier fal Hasso Cornet Richards tal tee Ayre aa obec Richart al Jeanings ot Jennings ‘eenacher et Amica Symone Garey Sento fier ca Caapeatort ‘nen eal Ste Searing a Andere ea Amen ta ‘Andee el ‘nde eal anand Sarena Sane eal Aarne ‘aoe Date wa ‘yrs oe ‘ners ea Andee al Fewer Andee a ‘Anion eal ‘Andre ea ‘Andee ealUS 10,240,089 B2 Page 3 (66) References Cited 6311454 BL 112001 Kempt 6327801 BL 122001 Chane USS. PATENT DOCUMENTS, 347.93 BL 22002 Xnderen eta eames ‘Xen st a: $3108 A 5/1997 Andersen ca. S280 Sshate Reed cima ec) Font ta S838292 A 61997 Jemings eal 647578 Nebesnak ta Sesraia A 61997 Jeanngs eal 6485's6b Date Sfeased A G'907 Andee ea e704 Aaesen ea. Seasm0 A T1997 Chen 6803751 Hush Ses07s A 81997 Willamson SSR Blah oa Sfeseous A 907 Andeacn eal. ssp Baum ea Sise60s A997 Andersen ea eso hema ea Siakoas A 81997 Andersen ea. shee Wredemann ea Sen900 A 81997 Anderen ea ssisioas hea Sfean90s A907 Andersen et a beh 901 Moyes See0.901 A 1997 Ameren a ‘507 Che, Sie 731A 9/1997 Anderen sa. 8699 Degelsezer Sfes439 A 911907 Andersen eta st 300 Fain S665:M2 A 91997 Antena a 588083 Les eta She905 A 101997 Andersen ea. se9607% Manten ea Bigo.4s A 101907 Andersen ea 628.80 Soane cea Sf70381 A 101997 Andersen ea BU 525 Aucvino Segn772 A 111897 Andenen a syeaens Walsh SeoSsil A 121997 Anderen eta. 766.621 Reppermund 3503787 A Lbrtvo7 Andersen ea 677.500 BL Gleam 8308203 A 1/1998. Adesen ea S88 BE Koons S308237 A 1/1998. Anderaen ea. s3ig0ss Ba S508236 A (908 Andersen et a e000 Bo Tame 308239 1/1998 Andersen ea 58660081 Nanda a S308242 A 1/1998. Andersen eal. 386.306 Chueh ea Soma A 1908. Andersen ea 590.604 Daniels Sou827 A 1/1998 Andersen ea 8361.998 rec ea. Sho90913 A 11895 Ameren a asa Taylor eta S711908 A 11998 ‘Tetentocher ea 981384 Deseloeasr S514217 A 2908 Andersen a Soss'on2 ani ca 8316675 A 21998 Andersen eal Jovo.07 Haney Soi42 A 21998 Monson Ben Adasen a S5m913 A 3908 Andee a. 7188468 hak tal 336.209 4/1998. Andersen ea. Janse hema tal S33921 A 411998. Andersen eal. past Kal etal Shanes A 4b98 Gite Teno hema eta S346522 A ‘S998 Espinora et a TK Aaesen 32014 Habe et a 38ste04 A 1D1D08 Audemen et a 8918083 B2 122014 Daniels Shak's24 A 121999, Anderaen eal. 82018 Daniels §y00722 A 31909. Andersen ea 2 BD 102016 Daniels Saba A ooo Racairarah bos 22018 Daniels com208 Soigom? A 61999 Tang 20010033367 AI” 102001 Senge a BOHR Hed eden donvioosr741 AL 122001 Glwson ota So7e235 A 11909. Andescn ea 2on200si7s7 a1 $2002 @inane7s A "32000. Andemen zanz00786s9 AL 62002 Ate aun2.o00%%5 AL $2002 Mayes et a eee aonaoi2uaer AL 93003 Fortinet al 3 tha Anieren @ at 20020128382 AL 912002 Soane eta. 6.11897 A 92000 Gomer aon20o166i79 At 102002 ang GiI94it A 9/000 Mater cit a aonsootsios AL ‘12003 Kius 646136 A 123000 Herbst 20030033786 AL 22003 Yulkowski GAGESS7 BI LV2001 Andeen ot aonsoosios9 AL $2003 Seuter et 180097 BI L2001 Andersen ta 2O0SOIISSI7 AL 62003. Backwell et a 6200404 BI 32001 Andersen et 2ons020sis7 AL 112003 Carton et 6231970 BI $2001. Andersen 2ons020e403 AL 112003 Daniels 6268022 BI 72001. Sehlegct eta Dooso2ti2si At 1/2003 Daniels 16299970 BI 102001. Richards ct a. 2ooso2ii2s2 At 1/2003, DaiesUS 10,240,089 B2 Page 4 66) References Cited wx ww0182 142010 & ont US. PATENT DOCUMENTS a teat a Mioeanrs "aod sooecoasies 122008 tee S Mose a 93013 pppgusics at 2004 den Somos Ay eae 20040231285 AL 11/2004 Hunt e¢ al. EP 1266877 AZ 12/2002 Sonosweo At 12atoy tack B Bes 2 'S2ni0 Siow at 3am bene B inims AL 52010 2005'0227006 AI 10°2005. Segall EP 2314462 AL 42011. Sonsoosisat At Im fst B ae AI 2013 Srsoswow AL 122008 Att wa & taser Al ig Bese at liane An SB Hows” one Sonoma At $06 in ° soars Sissy Soncoresee At $36 ann ta sooner ates Simos At wae AMIN ty * A So Somooststs At ‘Tau Gusta ” ets Sirois At 40 ® Birwwris Mt ar ” . Soros At Sar ® dwaoies Sorrcses At Sur Ca te 39 c Sirorssosy Al Gam tak ; ft dorolsrsy At Yama) Nesom sat i fooinsraa vat Sioa At samt Sean Sorrorgsizo At Bau? ua oe eae A Birosesees At Sar Blt wo moua2 at Jorwootes At TU Rips Sra oe ee Sommooeess At aioe es 2008 0027584 1/2008 Andersen et al. ae ee 20080027685 AI 1/2008 Andersen et al. wo 2007053852 AZ Somoosiony At 226 tyne a wo emesis Soimonwss At 3ato8 Sec a WO dimposirr At Biwease at aus pronana a wo Bounae A Somos: At Samos ess wo onweeig A Sommorgesso AI S206 Neha Wo dopoetn At Soro At Scion Mie Wo dopo At doors At 2m Bun gorkonscs Al 1106 Non ea mn PUBLICATIONS $20) ben S20 Gamat xen Seah Rap FP 136068 ted O16 2016 Blo faces al, D. Tapeimcal sa of xen yeih eomste 42010 Newt ‘it aot conn epnda pan” Pron Sas ad Soiporseses At Sa010 And ta ee ete Inroohae AL ainio Anion vac ron rN 200 Gl 3) 2011/0040401 ‘22011 Daniels pp. 267-273 7 Sonvorsos At 32011 Ape ta Fro Seach Report (KPO) PCTUSDOIS04 dat Silomust At aaolt hee sor 003 Bitores At SOIL Shen Intro Such Repr (KPO) FCTUSDIBOTI2 dt oipotten AI 1013 anes ee Soraoresy? AI $2013 Sma ae oleae AL 03013 Monk ii Saoh KR FETUSAH ogmmoris A 12003 Blman ian Such Rep (RIPO} FCTUS2OG8277 dat Sorsostesos AI $3013 beam Sep 2.2014, Bisons At wan Se Sch Rap PCTUSIP OS, da Ox. 42007, Sotsoooniss At "1014 Dana Sn Reba per sipesstss ome Ma 2s Sorsoumy AI 1014 basse Fear tended Sch Rept or EP S299 at, tawonist AL 1anls BEES a aotseenee! a au pane Ci ‘Supplementary European Search Report for EP 15803724 dated Jan. VOLOTIT2 AL 4/2015 Daniels et al 23, 2OIB. FOREIGN PATENT DOCUMENTS 101132999 a, Loin 986 22008 ‘ous XP 000375696 6001 Chemical Abstracts 117 (1992) Avg. 24, No, 8, Columbus, Ohio, US, Otce Acton [FP 138092823] dated Sep. 3, 2018. * cited by examinerU.S. Patent Mar. 26,2019 Sheet 1 of 12 US 10,240,089 B2 _._ ASee FIGS. 34-3D ZL. #See FIGS. 34-3DU.S. Patent Mar. 26,2019 Sheet 2 of 12 US 10,240,089 B2U.S. Patent Mar. 26,2019 Sheet 3 of 12 US 10,240,089 B2 104 = 402 + 404 + 406 + 408 FIG. 4 _. — See FIGS. 34-3D 104 = 402 + 404 + 406 + 408 + 502 _.—.#See FIGS. 34-30U.S. Patent Mar. 26,2019 Sheet 4 of 12 US 10,240,089 B2 104 = 402 + 404 + 406 + 408 104 = 402 + 404 + 406 + 408 + 702U.S. Patent Mar. 26,2019 Sheet 5 of 12 US 10,240,089 B2 _. —.#See FIGS. 3A-3D 104 = 402 + 404 + 406 + 408 _.— #See FIGS. 3A-3DUS 10,240,089 B2 Sheet 6 of 12 Mar. 26, 2019 U.S. Patent 9206. 206: 01 ‘Ola Zo04 10 zoL 807 80h + 90% + POF + ZOb = POL VOL ‘OldU.S. Patent Mar. 26,2019 Sheet 7 of 12 US 10,240,089 B2 1000 200, 300, 400, 500, * 600, 700, 800, 900 or FIG. 11¢ g833 FIG. 114US 10,240,089 B2 Sheet 8 of 12 Mar. 26, 2019 U.S. Patent “00s ‘OF ‘ove ‘00z ‘OOF 206 10 201 aZL “Old ooo 20.006 ‘008 ‘00z ‘00a _ vel “OldUS 10,240,089 B2 Sheet 9 of 12 Mar. 26, 2019 U.S. Patent 20630 201 ae “Old 0004 40 006 ‘008 ‘00 ‘009 _¢ “00s “Oar ‘0oe ‘o0z “OOF oes vel OldUS 10,240,089 B2 Sheet 10 of 12 Mar. 26, 2019 U.S. Patent fia ‘20650 201 Or, apt ‘Old 0004 20 006 ‘008 ‘002 ‘009 _a “008 ‘Oy ‘006 ‘002 ‘OOF vol ‘Old oor —*U.S. Patent Mar. 26, 2019 Sheet 11 of 12 US 10,240,089 B2 FIG. 15B FIG. 154US 10,240,089 B2 Sheet 12 of 12 Mar. 26, 2019 U.S. Patent ‘2109 J00p a4) 40 woyog @ 0} joued anyesooep puooes e uoey £ ‘100 4200p 24} Jo do} & o} jaued enjesooep sy e YoeNY £ 6-1 SLINDL Ul UMOYS Se 9109 J00p B APIO: 081 8 “Old yoedsau ‘wonog pue jooap puodes e pue jaued jeued JeqU29 yuersIsar @uy ay) Jo pus 4a 84) 0} 19p309 papnsyxe Ue Jo wed JS1y e YORNY ¥ Javed saqus0 yueysise1 a1y 94 pUE 4s9p10q qUeysise4 a1y pepniyxe eu 22n0 J0 eyeq Jeued 13}u30 jUeIs}821 224 a4 30 aprs pucoss ‘aun 0} Jepiog paprunxa ue Jo ays puddes e YOENY S021 yout pion enuso 5)804 314 PEPNAXO UE OPIADIe} Bujney sapiog yur ua puonas @ pue pus Ju © “aps puooas & ‘ap} ‘doy e ‘wonoq ® Bulney joued J91UN90 1 Optnose, = aoe Lola ZoLt = oe 91 oldUS 10,240,089 B2 1 GYPSUM COMPOSITES USED IN FIRE RESISTANT BUILDING COMPONENTS, PRIORITY CLAIM AND CROSS-REFERENCE, ‘TO RELATED APPLICATIONS This patent application is @ continuation application of US. patent application Ser. No, 14/542,930 fie on Nov. 17, 2014 and entitled “Gypsum Composites Used in Fire Resis: ‘ant Building Components”, now US, Pat, No. 9410361, ‘hich is a divisional application of U.S. patent application Ser. No. 13/610,542 flled on Sep. 11, 2012 and entitled stim Composites Used in Fire Resistant uilding Com ponents”, now U.S. Pat. No, 8,915,033, which isa comtiny- jn-in-part application of US. patent application Ser. No 603,405 filed on Sep. 4, 2012 and enitled “Gypsum ‘Composites Used in Fire Resistant Building Componcats” now U.S. Pat, No.9.375,899, which isa continuation in-part application of: (1) US. patent application Sor. No. 13/538, 788 filed on Jun, 29, 2012 and entitled "Fire Rated Doot ‘Core’: and (2) US. patent application Sex. No. 18/538,828 filed on Jun. 29, 2012 and entitled “Fire Rated Door”, now US. Pat. No. 9243.444. All these applications are hereby Incorporated by reference in their entirety, FIELD OF THE INVENTION The present invention relates generally to the fick! of ‘composite materials and, more particulary, gypsum com- Posites used in fie resistant building materials. BACKGROUND OF THE INVENTION ‘Many methods and techniques for manufacturing fire rated doors have been developed over time. But most of these prior art designs do not lend themselves well to fully auiomated manufacturing processes. Moreover, te prior at fire rated doors are expensive and require the internal mineral core. The internal core can be exposed in routed ‘details and may reduce the strength of the door a a result of the reluced thickness of the door panels. Inston, alig- ‘ment ofthe panels during assembly can be troublesome and regjire additional finishing to square the door after assem- bly. ‘Cement-based composites have been uscd in building materials for many years. For example, US. Pat. Nos. SS40,859, 5618341, 5.631.007, S41 S84, 5.658.624 5.702, 787, 5,766,525, 5,798,151, $849,155 and 6379446, and U.S.’ Published’ Patent Applications 20080099122, 201010136269 and 2011/0120349 describe various compo- sitions and processes for making extruded cement-based ‘composite prodnets, all of which are hereby incorporated by reference in their entity. ‘These patents and published patent applications, however, do not dislose fire resistant ‘composite components having the novessary fire resistant ‘capabilities to produce doors, door cores and building panels, that can receive fire ated certifications, SUMMARY OF THE INVENTION ‘The present invention provides fie resistant compowite ‘components having the necessary fire resistant capabilites to prxdnce doors, door cores and building panels that can receive fire rated cerifications. In most cases, he length and ‘Width of the fire rated door core will match the length and ‘width specifications of the final door product. The dimen- sons of the fire rated door core will typically be in widths 0 o 2 of thrwe feet and four fet and having length ranging eo ‘seven fect to ten fet. Te thickness othe fire core can range {rom 1.50 inches to 2.00 inches. In some eases, an exterior banding may be added to the sides and ends ofthe fire rated door core In othee cases, an intumescent banding. may’ be faded betwen the exterior banding and fie rated door core. ‘More specifically, the present invention provides @ com- posite predict including gypsum in an amotint of 60 to 90% by weight, fers in an amount of 1.5 to 26% by weight substantially homogeneously distributed through the com- posite, anda rheology-modifying agent in an amount of 5 {0 6% by weight. The composites caused or allowed to eure {o form a cured composite, The cured composite isa fre resistant component used in a fire-rated door eore, a fie rated door or a fire-ated building panel. The fie resistant component may include » building panel, 2 door panel 2 door core, 2 door ral, a door stile, door lek block, a door border, oF 2 door insert Tn addition, the present invention provides a composite product including gypsum in an amount of 60 to 88% by ‘weight, fibers in an amount of 1.5 to 5% by weight sub: stantially homogeneously distributed through the composite fn aggregate in an amount of 10 to 25% by weight substan- ‘ally homogeneously distributed through the composite, 9 starch in an amount of 2 to 7% by weight and a theology ‘modifying agent in an amount of 05 to 4% by weight. The composite is caused or allowed 10 eure to form a cured composite, The fire resistant component may include building pane, a door panel, a door core, a door ral, a door stile, a door Tock block, a door border, ora door insert used in a firemted door core, 2 fire-mted door oF a fre-rated building panel. "The present invention also provides ® composite product including gypsum in an amount of 70 to 90% by Weight, alas fibers in an amount of 2 10% by weight substantially homogeneously distributed tough the composite, cellulose fibers in an amount of 2 to 8% by weight substantially homogeneously distibuted through the composite, poly yl alcahol fibers in an amount of 1 to 4% by weight substantially homogeneously distibuted through the com- posite, polypropylene fers in an amount of 0.3 t0 4% by ‘weight substantially homogeneously distributed though the composite, and a heology-modifying agent in an amount of 0.5 to 6% by weight. The composite is cased or allowed 10 ‘ure to Tort cured composite. The fire resstant component may include a building panel, a door panel, a door core, & oor rail, door stile, door lock Block, a door border, oF 3 ‘door insert used ina fire-rated door core ie-rated door oF fa fie-rated building panel ‘Moreover, the present invention provides a core fora fire sated door that includes a fie resistant center panel and an extruded fre resistant border. The fire resistant exter panel ‘has abottom, a top a frst side, a sevond side, a first end and ‘second end. The fre resistant center pane! is made of first fre resistant material that includes gypsum in an amount of {60 10 85% by weigh, fibers in an amount of 1.5 10 5% by ‘weight substantially homogeneously distributed through the composite, an agaregate in an amount of 10 10 25% by ‘Weight substantially homogeneously distributed though the composite starch in an amount of 2 to 7% by weight and a rheology-modifying agent in an amount of 0.5 to 4% by ‘weight, The extraded fre resistant border is attached to the fist side, the socond side, the frst end and the second end ofthe fire resistant center panel. The extra fire resistant border is made of a second fire resistant material that ‘includes gypsum in an amount of 70 to 90% by weight, glass fibers in an amount of 2 to 10% by weight substantiallyUS 10,240,089 B2 3 homogeneously distributed through the composite cellulose fibers in an amount of 2 10 8% by weight substantially homogeneously distributed through the composite, polyvi- ryl alcohol fibers in an amount of 1 to 4% by weight substantially homogeneously distributed through the ca posit, polypropylene fibers in an amount of 03 10 4% by ‘weight substantially homogeneously distributed through the ‘composite, and a rheology-modifying szent in an amount of 05 to 6% by weight, “The present invention also provides a fire rated door that includes # core, a first decorative panel and a second decorative panel, The cor includes: (a). ire resistant center pane] having a bottom, top, a firs side, second sie, fst ‘end and a second end, wherein the fie resistant center panel ‘made of fist ie resistant material that ineludes gypsum inn amount of 60 to 85% by weight, bers in an amount ‘of 15 to 5% by weight substantially homogeneously dis tributed through the composite, an aggregate in an amount ‘of 10 to 25% by weight substantially homogeneously dis tributed through the composite, a starch in an amount of 2 to 7% by weight and a theology-modifying agent in an amount of 05 to 4% by weight, and (b) an extruded fre resistant border attached to the first side, the second side, the first end and the second end ofthe fire resistant center pal wherein the extruded fire resistant border is made of second fie resistant material that includes gypsum in aa amount of 70 to 90% by weight, glass fibers in an amount ‘of 210 10% by weight substantially homogencously distrib uted throvgh the composite, cellulose fibers in an amount of 2 wo 8% by weight substantially homogeneously distributed through the composite, polyvinyl aleohol fibers in. an amount of 1 to 4% by weight substantially homogeneously slistibuted through the composite, polypropylene fibers in ‘an amount of 03 10 4% by weight substantially homoge- neously distributed throvgh the composite, and a rheology ‘modif¥ing agent in an amount of 05 to 6% by weight. The first decorative pane! is attached to the top of the fire resistant center panel and the extruded fire resistant border. The second docoratve panel i attached tthe bottom of the fire resistant center panel and the extruded fire resistant border. “The present inveation is deseribed in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS ‘The above and furer advantages ofthe invention may be better understood by referring tthe following description in ‘conjunction with the accompanying drawings, in which: IG. 1s. perspoctve view ofa door core fora five rated door in secordance with one embodiment of the present TIG, 2s. perspective view of a door core fora fie ated {door in accordange with another embodiment of the present TIGS, 34-39 are eross-sectional views of various inter- faces ofthe center panel and the border of a door core in secondance with one embodiment ofthe present invention; TIG. 4s perspective view ofa door core for a fire rated «door in accordance with another embodiment of the present invention; TIG. 3 i. perspective view of a daor core fora fire rated door in accordance with another embodiment ofthe present FIG. 6s. perspective view ofa door core fora fie rated door in accordance with another embodiment of the present invention: 0 o 4 FIG. Tis a perspective view of a door core Fora fire rated door in accordance with another embodiment of the present FIG. 8s a perspective view ofa door core fora fire rated door in acconlance With another embodiment of tke present FIG. 9 is a perspective view of a door core fora fire rated door in accordance with another embodiment of the present invention; FIG, 104 isan exploded perspective view of door eore for a fire rated door in accordance with another embodiment of the present invention FIG. 108 is a cross-sectional view of the door core of FIG. 10A; FIG. I1A is an exploded perspective view of a fire rated door in accordance with one embodiment of the present invention: FIG. 11B is a erossseetional view ofthe fit rated door of FIG. LA; FIG. HC is a cross-sectional view of an alternative version of the fire rated door of FIG. 1A FIG, 12A is an exploded perspective view of a fire rated door in accontance with another embodiment of the present invention: IG. 129 is a erost-sectional view of the fire med door of FIG. 124; FIG. 13A is an explodes perspective view of a fre rated door in accordance with another embodiment of the present FIG. 13B is a erosssectional view of the fire rated door of FIG. 134; FIG. 13C is @ cross-sectional view of an alternative version of the fire red door of FIG. 13; FIG, 144 is an exploded perspective view of a fire rated door in aecontance With another embodiment of the present invention: FIG, 14B is a cross-sectional view of the fire rated door of FIG. 144; FIG. 14C is a cross-sectional view of an alternative version ofthe fire rated door of FIG. 144; FIG, 15, is an exploded perspective view of a fire rated door in accordance with another embodiment of the present FIG. 15D is a erost-scctional view of the fire mted door of FIG. 184; FIG. 16 is @ flow chart of « method of manufacturing 3 door core for a fire rated door in accordance with one embodiment ofthe present invention: FIG. 17 isa flow char of a method of manufacturing a door core fora fire rated door in accordance with another embodiment of the present invention; and FIG. Iisa ow chart of method of manufacturing ie rated door in. accordance with one embodiment of the present invention, DETAILED DESCRIPTION OF THE, INVENTION While the making and using of various embodiments of the present invention ae diseussed in detail blow, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a ‘wie variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways 10 ‘make and wse the invention and do aot delimit the seope of the invention, The discussion herein relates primarily to freUS 10,240,089 B2 5 rated doors, but it willbe understood that the concepts ofthe present invention are applicable to any type of door. ‘The composite product of the present invention provides fire resistant components having the nocessary fire resistant ‘capabilities to produce doors, door cores and building panels, that can reccive fire rated certifications. The composite includes gypsum in an amount of 60 to 90% by weight, fibers in an amount of 1.5 t0 26% by weight substantially hhomogeneovsly distributed through the composite, and 2 rheology-modifying agent in an amount of 05 10 6% by weight, The gypsum can be 60%, 619%, 62%, 63%, 64% 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74% 15%, 76%, 7a, 78%, 79%, BOM, 81%, 82%, RIM, 84% 85%, 8696, 872%, 88%, 89% oF 90% by weight oF other incremental percentage betwecn, The fibers can be 1.5%, 2%, 2.5%, 386, 3.58%, 46, 4.5%, 59%, 5.5%, 6%, 6.59%, 7%, 7S, 8%, 8.5%, 9%, 9.5%, 10%, 10.5%, 11%, 11.59%, 12% 12.5%, 13%, 135%, 14%, 14.5%, 13%, 165%, 179 percentage between. The fibers can he glass fibers, cellulose {Thers polyvinyl alcohol fibers, polypropylene fbers, or 2 ‘combination thereof. Other types of fibers can be used. The > rheology-modifving agent ean be 0.5%, 0.6%, 0.7%, 08% 09%, 1% 11%, 1.2%, 13%, 14% 15%, 1.6%, 17%, 18%, 1.9%, 296, 2196, 22%, 23%, 24%, 2.5%, 2.6%, 24, 28%, 2.9%, 3%, 3.1%, 3.296, 3.3%, 3.496, 3.5% 3.6%, 3.7%, 38%, 3986, 496, 4.1%, 429%, 4.3%, 44% 415%, 4.6%, 47%, 48%, 4.9%, 596, 519%. 5.296, 53% 5.4%, 5.5%, 5.6%, 5%, 58%, 5.9% or 6 by weight oF other incremental percentage between, The rheology-mad ‘ving agent can be bydroxypropos! methyl celuose (HPMC), methyl hydroxyethy] cellulose (MHEC), hydrexy- ‘ethyl celulose (HEC) or carboxymethyl cellulose (CMO), ‘Other types of theology-modifying agent ean be used. “The composite is caused oF allowed 10 eure 10 form 9 ‘cured composite, The actual component weights used wil, ‘depend on the density desired forthe fie resistant compo~ rent, The cured composite sa fire resistant component sed in a firezated door core, a ire-ated door of a fie-rated building panel. The fie resistant component may incade @ building panel, a door panel, a door core, a door rail, « door stile, a door lock block, a dor border, ora door insert. The fire resistant component typically has a cross-sectional thickness of 0.125 inches to 2 inches, a width of | inch to 4 feet and a length of 310 10 feet. Moreover and unlike many prior art composite materials, the composite product in accordance with the present invention does not include any ‘cement of yas ‘The door core of the present invention provides the fire resistant cupabilties necessary to receive the necestary ‘certification, The length and with of the fire core will match the length and width specifications ofthe final door pret. ‘The dimensions of the fre core will typically be in widths of three feet and four feet and having a length ranging from seven feet to ten feet. The thickness of the door core will ‘ypically be between 0.125" and 1.5". A door manufacturer ‘can use any’ of the completed core designs deseribod herein ‘8 the fire resistant core of the manufacturer's fte-rated ‘door. The resting fie rated door ean have fire ratings of 20-30, 45, 60, 90 or 120 minutes depending on the eontign- ration and materials wed, The manufacturer will typically finish the final door precuct by adding a final pieve of wood ‘or vencer fo the dcr to provide the aesthetic appeal of the product. o 6 [Now refering to FIG. 1, perspective view ofa door core 100 fora fie rated door in accordance with one embodiment of the present invention is shown. The core 100 includes 2 fire resistant center panel 102 and an extrac fire resistant border 104, The fire resistant center panel 102 has «bottom (not shown), a top 106, a frst side 108, a second side 110 first end 112 and a second end 114. The fre resistant center panel 102 is made of a frst fire resistant material that is either pourable or extrude. The first fre resistant material ean be composed of gypsum, water, ulas, a eeramie mate- Fal, 9 cellulose of fiber material and one oe more binding agents. One example of such a material in nevordance with the present invention is ie Fe Rear Maer Conn Raase 1) ‘pan eas awe Ase 0102s ‘Sanh 267 Ricloy-Moifng Ags nstes “The gypsum can be 60%, 61%, 62%, 63%, 68%, 65%, 66%, 6%, 6895, 69%, TOM, 71%, 72%, 739%, TAY, 75%, 16% 7M, T8%, 79%, BOM, $1%, 82%, $34, 84% oF 85% by ‘weight or other incremental percentage hetwcen, The glass fibers can be 1.58%, 2%, 2.5%, 39%, 3.58, 4%, 45% oF 5% bby weight or other incremental percentage between. The alass fibers ean have a diameter of 6 mm to 25 mm. The lightweight aggregate can be 10%, 119%, 12%, 13%, 149%, 15%, 16%, 17%, 18%, 198%, 20%, 21%, 229%, 23%, 24% oF 25% by Weight or other ineremental percentage between, The lightweight aggregate, such as PoraverE| porous glass spheres, can have average particle diameters of | to 2 mma ‘or 2 to 4 mm, The starch ean be 2%, 2.5%, 3%, 3.5%, 4%, 4.5%, 58, 5.5%, 6M, 6.5% oF 7% by weight or other ‘neremental percentage between. The starch is pregelat nized or cook-up starch The theology-modiying agent can be cellulose ether, such 2s hydroxypropoy! methyl eelluose (EPMO), methy hydroxyethyl cellulose (MHEC), hydroxy- thy! cellulose (HEC), carboxymethyl cxlulose (CMC) or similar materials, The rheology-modifying agent can be 05%, 0.6%, 0.7%, 08%, 0.9%, 1%, 1.1%, 12%, 13%, 14%, 1.5%, 1.6%, 1.7%, 18%, 1.9%, 2%, 21%, 22%, 23%, 2.4%, 25%, 2.6%, 27%, 28%, 2.9%, 3%, 31%, 3.2%, 33%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9% oF 4% by ‘weight or other incremental percentage benween. A vermiw- lite or clay can als be included in the composition in 0%, 1%, 29, 3%, 4%, 5%, 6%, 7%, 8%, 9% oF 10% by weight or other incremental percentage between. Other materials «an be substituted as will be appreciated by those skilled in the art, ‘The extnided fire resistant border 104 is made of a second fire resistant material having & higher density than the frst fine resistant material so dh second fire resistant material has holding capacity (eg. fasteners will adhere to the second fire resistant material and remain fixed once installed) and ean be shaped using an extrusion process. One ‘example of sich material in accordance with the present invention isUS 10,240,089 B2 7 ‘pu Two ts Fe ao Polyvinyl Aeotiol (PVA) Fiber tod Potyrpyiee (P) Eee ostoa hogy Mote Ags nse ‘The gypsum can be 70%, 71%, 72%, 73%, 78%, 75%, 76%, T7M%, 78%, 79%, BOM, 81%, R26, RIM, BAY, 859%, 86%, 87%, 88%, 89% or 90% by weight of other ineremental pereentage between. The glass fibers ean be 2%, 2. 3.5%, 4%, 4.5%, 5%, 5.5%, 6%, 6.5%, 7, 7.59%, 89 9%4, 9.5% oF 10% by weight or other incremental percentage between, The plas bers ean have a diameter of 6 mit to 25 mim. The cellulose fibers can he 2%, 25%, 3%, 3.5%. 4%, 4.5%, 5%, 5.5%, 64, 6.5%, 7%, 7.5% or 8% by weight oF other incremental persentage between, The celllose fibers ‘ean be hardwood or softwood fiber. The polyvinyl alcohol (PVA) fibers can be 1%, 1.5%, 2%, 2.5%, 3%, 3.5% oF 4% by weight or other incremental percentage Between. The VA fibers can have a diameter of 6 mm to 10 mm with @ “decitex of approximately 15. The polypropylene (PP) fibers ‘ean be 0.5%, 0.6%, 0.7%, 0.8%, 0.98%, 1%, 11%, 12%, 13% 1.4%, 1.5% LO, 1.7%, 18%, 1986, 2%, 2.1%, 22%, 23%, 24%, 25%, 20%, 2.7%, 28%, 29%, 3%, 53.1%, 3.2%, 3.3%, 349%, 3.596, 3.6%, 379%, 3.8%, 3.9% oF 44% by weight or other incremental percentage between. The DP fibers ean bave a diameter of 6 mm to 25 mm, The theology-modifying agent can be 0.5%, 0.6%, 0.7%, 08%, 0.9%, 1% 1.1%, 1.286, 1.3%, 1486, 15%, 1.6%, 17%, 189%, 1.9%, 294, 21%6, 22%, 2.39%, 24%, 2.58%, 2.6%, 2.7%, 28%, 2.9%, 3%, 3.19%, 3.2%, 33%, 3.4%, 35%, 3.6%, 3.7%, 3.8%, 3.9%, 4%, 4196, 42%, 43%, 4.9% 45%, 4.6%, 47%, 48%, 4.9%, 5%, 51%, 3.2%, 5.3% 5.4%, 5.5%, 5.6%, 5.7%, 58%, 5.9% or 6% by weight oF ‘ther incremental pereentage between, The rheology-modi ‘ying agent can be a cellulose cer, such as hydroxypropyl methyl cellulose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethy] cellulose (HEC), carboxymethy] ‘ellulose (CMC) or similar materials. Other materials ean be substituted as wil be uppreiated by those skilled inthe a. “The extedled fie resistant border 104 ean be made of 3 molded piece ofthe socond fire resistant material (¢., FIG. 1), or stiles and rails made of the second fire resistant material that ae glued of fastened Together (ex, FIG. 4). The extruded fire resistant border 104 is attached to the firs, side 108, the second side 110, the fist end 112 and the second end 114 ofthe fire resistant center panel 102 using ue, fasteners or a bonding process (eg. pouring the frst fir resistant material into “mold” formed by the extruded fre resistant border 104). Several examples of the imterface between the extnaded fire resistant border 104 and the fre resistant center panel 102 are shows in FIGS, 33D, The physical dimensions of the core 100 and other cores described below in reference to FIGS, 2-10A and B, the fire resistant center panel 102 and the extruded fire resistant border 104 will vary depending on the specific application or which the door ere is mansfacture. Typical dimensions may inelude, but are not Fimited to, 1.5" to 20" thickness of the fire resistant panel 102 and the extraded fire resistant border 104, a 7 10 10' overall length ofthe core 100, a 3'10 4 overall width ofthe core 100, 1" to S* width ofthe top ‘and bottom portions (rails) of the extruded fire resistant 0 o 8 border 104, and a 1" to 5" (eg. 1.625") width ofthe left and ‘ght portion (tls) of the extruded fre resistant border 104 "The cote 100 and other cores described below in reference to FIGS. 2-10A and B ean be mantfsctured by assembling the fie resistant border 104, pouring the frst fire resistant ‘material in the area formed by the fire resistant border 1D, And baking the core 100- Alternatively, the coe 100 can be ‘manufactured by creating sheets of the first fre resistant ‘material and the second fire resistant material using an fextnision process, gang ripping the sheets of the second fire resistant material to make the lite resistant border stiles and rl, finishing the extruded stiles and nls to profile or cut them fo the desired smoothness, size and shape, and gluing ‘or fastening the fire resistant border stiles and rail othe fre resistant center panel 102 Referring now to FIG. 2, perspective view ofa door core 200 fora fee rated door in accordance with another embed ‘ment of the present invention is shown. The core 200 ‘includes first fie resistant eenter panel 102e, a second fre resistant center panel 1026 and an extnided fire resistant border 104. The first fire resistant center panel 102a bas a bottom (not shown), a top 1064, a first side 108, a second side 1102, a frst end 112 and a second end 202. The second fire resistant center panel 1026 has a bottom (oot shown), top 1065, a fist side 108%, socond side M104, a fist end 204 and a second end 114, The fist fire resistant center panel 102a and second fire resistant center panel 1025 are madeof | the frst fre resistant material tha is ether pourable or texinidable, The extradd fre resistant border 104 is made of the second fire resistant material having a higher density than the fist fire resistant material so that second fire resistant material has holding eapacity (e., fasteners will adhere tothe second fire resistant material and remain fixed ‘once installed) and can be shaped using an extrusion pro- cess. The extrided fire resistant border 104 alsa includes ‘eater rail 206 made ofthe second fire resistant material. The fexinided fre resistant border 104 can be made of a molded piece ofthe second fire resistant material (eg, FIG. 2), or Stiles and rails made of the sccond fie resistant material that are glued or fastened together (eg. FIG. 5), The extruded fire resistant border 104 (including center rail 206) is attached tothe first side 108a, the second side 11a, the first fend H12a and the second end 202 of the fie resistant center ‘panel 102a andthe first side 1086, the second side 1106, the Tint end 204 aad the second end 114 of the second fire resistant center pane! 1026 using glue, fasteners ora bonding process (ei, pouring the first fre resistant material into 9 “mold” formed by the extruded fire resistant border 104), Several examples of te interface between the extruded fre resistant border 104 and the fire resistant center panels 1022, 102) are shown in FIGS. 3A-2D. ‘he physical dimensions of the core 200 and other cores scribed below in reference to FIGS. 3-10A and B, the fre resistant center panels 102a, 1025 and the exinided fire resistant border 104 will vary depending on the specitie pplication for which the door core is manufactured. Typical dimensions may include, but are not limited to, 1.5" thick- ‘ess o the fire resistant panels 1022, 102 andthe extruded fine resistant border 104, 7 o 10 overall length of the core 100, 23 t0 4" overall width of the core 100,21" to $* width ‘of the top, bottom and eenter portions (ails) ofthe extruded fire resistant bonder 104, and aI" t0 5" (eg, 1.625") width of the left and right portion (stiles) of the extruded fire resistant border 104 Now referring to FIGS. 3A-3D, enoss-setional views of various interfaces of the center pane! 102 and the border 104 ‘of a door core 100, 200, 400, 00, 600, 700, 800 and 900 iaUS 10,240,089 B2 9 ‘aeconlance with one embodiment of the present invention is show FIG, 3A shows a stmight interface witecin a ghic is used to attach the extroded fire resistant border 104 to the fire resistant center panel 102, Note that the straight interface ‘can be angled with respect fo the top of the fire resistant ‘center panel 102 instead of being substontally perpenlcn Jar. As'shown in FIGS. 3B-3D, the extruded fre resistant border 104 att he altaced tothe fire resistant center panel 102 witha set of male-female connectors 300 Formed in the ‘exude fre resistant border 104 andthe fire resistant enter pane] 102, The male-female connectors can be wiangular- shuped 3002 (FIG. 32), curved -shuped 3006 (FIG. 3C) or 300e (FIG. 3D), rectangular-shaped, angled, tongue-and- trove, ora combination there. glue is typically used is used to attach the extroded fire resistant border 104 to the fire wsstant center panel 102, but fasteners or a bonding process can also he used, ‘Referring now to FIG, 4, perspective view ofa door core 400 fora fre rated door in accordance with another embod ment of the present invention is shown. The core 400 ‘nchides fre resistant center panel 102 and an extraded fre resistant border 104, The fre resistant center pane 102 has a bottom (not shown). a top 106, a first side 108, a second ide 110, 8 frst end 112 and a second end M4. The fre resistant center panel 102 is made of the frst fire resistant material that is either pourable or extrudable, The extruded fire resistant border 104 is made up of frst stile 402 (let), a second stile 404 (right), fist rail 406 (lop) and a second, rail 408 (bottom). The ist stile 402 (lef), second stile 404 (ight), fist rail 406 (op) and second rail 408 (bottom) are ‘made of the second fire resistant material having a bigher ‘density than the ist fire resistant material so that second fire resistant material has holding eapacity (eg., fasteners will ‘adhere to the second fre resistant material and remain fixed ‘once installed) and can be shaped using an extrusion pro- ‘ess, The frst stile 402 (let), seeond stile 404 (right), Hist rail 406 (op) and second rail 408 (bottom) are glued or fastened together and to the fre resistant center panel 102. ‘The fist stile 402 (lef) is atached to the fist side 108 ofthe fire resistant conter panel 102 using glue, fasteners or bonding process, The second stile 404 (ight is attached to the second side 110 of the fire resistant center panel 102 using glue, fasteners ora bonding process. The fist rail 406 (Gop) is attached tothe first end 112 ofthe fe resistant center panel 102 using glue, fasteners oF « bonding process, The second rail 408 (top) satached fo the second end 114 of the fire resistant center panel 102 using glue, fasteners or a bonding process, Several examples ofthe interface between the stiles 402, 404, the rails 406, 08, and the fire resistant ‘enter pane! 102 are shown in FIGS. 3A-3D. ‘Now relerring o FIG. 8, a perspective view ofa door core 500 fora fre rated door in accordance with another embod ment of the present invention is shown. The core 500 ‘nchides« ist fire resistant center panel 102a, a second fre resistant pane] 1026 and an extruded fire resistant border 104, The first fire resistant center panel 1022 has a bottom (oot shown) a top 1064, a frst side 1084, second side 10a, a fist end 12a andl second end 202. The second fre resistant center panel 102% has bottom (ot shown), top 106, a fist side 1080, a second side 110, fist end 204 ‘and a second ead 114. The frst fire resistant center panel 102a and socond fire resistant center panel 102H are made of the frst fre resistant material that is ether pourable oF ‘extrudabe. The extradd fre resistant border 104 is made up ‘ofa ist stile 402 (lef), a second stile 404 (igh) frst rail, 1406 top).a second rail 408 (bottom) anda third ral or insert 502 (ceoter) The first stile 402 (let), secoad stile 404 0 o 10 (ight, frst ral 406 (lop), second rail 408 (boom) and third rail of insert $02 (center) are made of the second fire resistant material having a higher density than the frst fire resistant material so that second fire resistant mteral has holding capacity (eg, fasteners will adhere to the second fire esstant material and remain fixed once installed) and canbe shaped using an extrusion process. The frst stile 402 (let), second stile 404 (right), steal 406 (top), second eal 408 (bottom), third rail oe inseet $02 (center) axe glued or fastened together aod tothe fire resistant center panels 102 ‘and 1026, The first stile 402 (et) is attached to the frst side 1082, 1085 of the fre resisiant center panels 1020, 1025 ‘using phe, fasteners or a bonding process, The second stile 404 (ight) is attached tthe second side 110a, 1106 of the fir resistant center panels 1022, 1026 using give, fasteners ‘or a ending process. The first rail 406 (top) is aitached to the frst end 112 of the frst fre resistant center panel 1024 using glue, listeners or a bonding process. The second rail +408 (bottom) is attached 1 the second end 114 ofthe second fire resisant center panel 102 using glue, fasteners or a bonding process. The third rail or inser. 802 (center) is ‘attached tothe second end 202 ofthe fis ire resistant center panel 102a and the fist end 204 of the second ie resistant panel 1026 using glue, fasteners or a bonding process. Several examples of the interface between the stiles 402, 4404, the rails 406, 408, and the fire resistat center panels 1022, 102 are shown in FIGS. 3A-3D. These interfaces can also be used between the fie resistant center panels 1020, 102 and the third rail oF insert $02 (center). Referring now to FIG, 6, perspective view ofa door core {600 fora fire rated door in accordance with another embodi- ‘meat of the present invention is shown. The core 600 includes a fire esistant center pane! 102, an extruded fre resistant border 104 aad a lock block 602. "The fire resist center panel 102 as a bottom (901 shows), atop 106, a first ‘ide 108, second sce 110, a frst end 112, second end 14 And « cutout or notch 604 disposed in the fist side 108. The fire resistant center panel 102 is made of the first fire resistant material that is either pourable or extradable. The Jock block 602 is disposed within the eutout or notch 604 of the fire resistant center pancl 102. The lock block 602 is ‘made of the second fire resistant material and js sized 10 acommodatea door han, lockset or other door hardware ‘The extended fre resistant border 104 is made up ofa fi stile 402 (eft). second stile 404 (right). a frst rail 406 1p) and a second rail 408 (bottom), The fist stile 402 (left), second stile 404 (eight), fist rail 406 (op) and second ral 408 (bottom) are made ofthe second fre resistant material having a higher density than the frst fre resistant material 0 that second fie resistant material has holding capacity (eg, fasteners will adhere 0 the second fire resistant ‘material and remain fixed oace installed) and ean be sbapod using an extrusion proces, The frst stile 402 (lel), second stile 404 (eight), fist rail 406 (top) and socond rail 408 (ottom) are glued oF fastened together and to the fre resistant center panel 102 and lock block 602. The firs stile 402 Let isatached tothe frst side 108 ofthe fire resistant center pane! 102 and the lock block 602 using glue, Fasteners ‘ora bonding process The second stile 404 (right) is attached to the second side 110 of the fire resistant center panel 102 using glue, festeners or a bonding process. The first rail 406 (Gop) is atachod to the frst end 112 ofthe fre resistant conter panel 102 using glue, fasteners or a bonding process. The Second rail 408 (top) is attached tothe second end 114 ofthe fire resistant center panel 102 using glue, fasteners or a bonding process. Several examples af the interface between the stiles 402, 404, the rls 406, 408, snd the fie resistUS 10,240,089 B2 ul ‘center panel 102 are shovin in FIGS, 3A-3D, These inter- faces can also be used between the lock block 602, the fre resistant center panel 102 and the fist stile 402 (lef), "Now refering to FIG. 7, a perspective view ofa door core 700 fora fre rated door in accordance with another embodi- ment of the present invention is shown. The core 700 ‘includes first fire resistant center panel 12a, a second fre resistant panel 1025 and an extraed fie resistant border 104. The first fire resistant center panel 102a has a bottom (oot shown), a top 106a, a first side 1080, a second side 110; fist end 112a ancl second end 202. The second fre resistant center panel 102% has a bottom (not shown), atop 196, a first side 1085, a socond side 1105, a fest endl 204 ‘and a seoond end 114. The frst fire resistant center panel ‘020 and second fit resistant center panel 102 are made of the first fire resistant material that is ether pourable oF ‘extrudable. The extruded fire resistant border 104 is made up ‘of a first slle 402 (left) a second stile 404 (igh) irs ail, 406 op) second rai 408 (bottom) snd thir rail or insert Wx (aikddle). The fies stile 402 (el), second stile 404 2 (Fight, irs rail 406 (op), second rail 408 (boom) ancl third rail or insert 702 (middle) are made of the second fire resistant material having higher density than the fst fre resistant material so that second fie resistant material has holding capacity (e.g, fasteners will adhere tothe second fire resistant material and remain fixed once installed) and ‘canbe shaped! using an extrasion process. The first stile 402, (leh), second stile 404 (ht), rst rall 406 (op), second rail 4408 (botiom), third mail or insert 702 (middle) are ged or fastened fogether and tothe fre resistant center panels 102 and 102b. The first stile 402 (lel) s attached to the frst side 10Ka, 108 of the fire resistant center panels 1020, 1025 using gle, fasteners or a bonding process. The second stile 404 (right) is attached tothe second side 11a, 106 ofthe fire resistant center panels 1024, 1026 using glve, fasteners ‘ora bonding process, The fist ral 406 (op) is attached (0 the first end 112 of the frst fre resistant center panel 102a using ghie, fasteners or a honding process, The second rail 408 (bot) is attached tothe second end 114 of the second, fire resistant center pane] 1026 using glue, fasteners or 2 bonding process, The thint ail or insert 702 (eile) is tached 10 the second end 202 of te ist fire resistant center pane! 102a and the first end 204 of the second fire resistant pane] 1026 using glue, fasteners or a bonding process. The third rail or insert 702 (middle) i positioned and sized (eg to 10" wide) t0 accept various atachments, such as & ‘rash bar. Several examples of the interface between the Stiles 402,404, the ails 406, 408, anl the fire resistant center panels 1022, 1025 are shown in FIGS. 3A-3D. These Interfaces ean also be used between the fire resistant center panels 1029, 102h andthe third rail or insert 702 (aida). ‘Referring now t FIG. 8, perspective view ofa door core 800 fora fre rated door in accordance with snother embodi- ment of the present invention is shown. The core 800 Includes a first fire resistant center panel 102a, a second fre resistant center panel 102b, an extruded fre resistant border 104 and a lock block 602, The fest fire resistant center panel 1020 fis a bottom (n0t shown), atop 1064, frst sie 1084, ‘a second side 110a,a fist end 1124, a second end 202 and 8 cutout oF notch 604 disposed in the first side 1084. The second fire resistant center panel 1026 las a bottom (not shown), atop 1066, a firs sido 108, a second side 1105, 2 first end 204 and second end 114, Tho fist fire resistant ‘center panel 102a and second fire resistant center panel 1028 fare made of the first fre resistant material that is ether pourable or extrudable. The lock block 602 is disposed tue euout or notch 604 ofthe firs ire resistant cea 0 o 12 panel 1024, The lock block 602 is made of the second fre Fesistant material and is sized to accommodate 3 door handle, ockset oF other door hardware, The extruded fire resistant border 104 is made up of a first stile 402 (lef), a second stile 404 (eight), frst rail 406 (top), a second eal 408 (bottom) ana third rail or insert 702 (sede). The frst stile 402 (leh), second stile 404 (right), first rail 496 (tp), second ail 408 bottom) and third eal or insert 702 (mille) fare made ofthe second fire resistant material having higher ‘density than the frst fire resistant material so that second fre resistant material has holding eapoeity (eg, fasteners will adhere tothe second fire resistant material nd remain fixed ‘once installed) and can be shaped using an extrusion pro- cess, The fist stile 402 (lft), second stile 404 (right), frst rail 406 (top), second rail 408 (bottom), thi ral or inset ‘M2 (middle) are glued o¢ fastened together and to the fre resistant center panels 1024, 102b and lock block 602. The first sie 402 (Left is attached tothe first side 108a, 108 of the fire resistant center panels 102a, 102b andthe lock black 602 using glu, fasteners or a bonding process. The second stile 404 (ight) is attached to the second side 110a, 1105 of the fire resistant center panels 102a, 1026 using glue fasteners or a bonding process. The first ail 406 (top) is attached to the firs endl 112 of the first fre resistant center ‘panel 102a using glue, fasteners or a bonding process. The second rail 408 (bottom) is attached to the second end 114 fof the second fre resistant center panel 102) using glue, fasteners or a bonding process. The third rail or insert 702 (middle) is attached to the socond end 202 ofthe first fre resistant center panel 102a, the first end 204 of the second fire resistant panel 102b and the lock block 602 using ghic, fasteners or a bonding process. The third ral or insert 702 (middle) is positioned and sized (eg., 5" 19 10" wide) t0 accept various attachments, such as a erash bar. Several ‘examples of the interface between the stiles 402, 404, the ‘ils 406, 408, ad the fire resistant center panels 102a, 1025 fare shown in FIGS, 34-3D. These interfaces ean also be ‘used borwoen the lock block 602, the fie resistant center ‘pane! 102a, the frst stile 402 (Left) andthe third rail or insert ‘2 (middle). [Now referring to FIG. 9, aperspective view ofa danr core ‘900 fora fice rated door in accordance with another embed sent of the present invention is shown. The core 900 includes a center panel 902 and an exteuded fre resistant border 104, The egater panel 902 ass botlom (not shown), ‘top 106, fst side 108, 9 second side 110, a first end 112 fand'a second end 114, The center panel 992 is mode of @ corrugated filer (e., caniboard, et.) having a plurality of voids (e.2, honeycomb shaped, hexagon shaped, triangular shaped, et.) andl may be filed with an acoustical insulating rateral (eg. fbemlass, foam, etc). The extruded fire resistant border 104s made up of a first stile 402 (lef), « second stile 404 righ) frst rail 406 (op) and a second eal 408 (bottom). ‘The fist stile 402 (le), second stile 404 (ight, frst rail 406 (Lop) and second rail 408 (bottom) are ‘made of the second fire resistant material having a higher density than the first fire resistant material so that second fre resistant material has holding eapacity (eg, fasteners will adhere tothe second fire resistant material and reas fixed ‘once installed) and can be shaped using an extrusion pr cess. The fis stile 402 (left), second stile 404 (right), rail 406 (top) and second rail 408 (botiom) are glued or ‘stoned together andl to the center panel 962, The first stile 402 (Left is attached tothe first side 108 ofthe center panel ‘92 using ge, fasteners ora bonding process. The second stile 404 (right) is attached to the second side 110 of the ceeater pane! 902 using plue, fasteners ora bonding process.US 10,240,089 B2 13 The first rail 406 (tp) is attached to te frst end 112 of the ‘center panel 902 using glut, fasteners ora bonding process ‘The second rail 408 (top) is atached to the second end 114 ‘of the center panel 902 using glue, fasteners or a bonding. process, Several examples of tho interface beeen the tiles 402, 404, the rails 406, 408, and the fire resistant center pane] 902 are shown in FIGS. 34-8D. Note that the center panel 902 is not suitable for forming a fire resistant door lone. Fire resistant materials or panels must be installed on the top 106 and bottom (not shown) ofthe center panel 902 ‘inorder to make‘ fre resistant door For example, the center pane] 902 can be used ia the doors 1100 (EG. 11), 1200 (FIG. 124) and 1300 (FG. 134) if panels 1102, 1102 and 1302, respectively, are made ofa fie resistant material (@. the second fre esistant materia, ete). Referring now 10 FIG. 10, an exploded perspective view ‘of door core 1900 for a fie Fated door in accordance with snother embodiment of the present invention is show The ‘core 1000 includes a fre resistant center panel 102 or 1002 disposed between a top insulating panel 902a aad a hoon, insulating panel 9028, and an extrided fire resistant hordce 104 around the three panels 902a, 102 (or 1002) and 9026. “The fie resistant center pane! 102 is made of the first fire resistant material tht is either pourable or extradable. The fire resistant center panel 1002 is made of the second fire resistant material that is either pourable or extrwlable. The ‘op insulating pane! 992. and bottom insulating panel 9025 are made of a corrugated lle (e-¢ cardboard, et.) having a plurality of voids (eg, honeycomb shaped, hexagon shaped, triangular shaped, ete.) and may be filled with an acoustical insulating material (¢., beglass, foam, ct.) The three panels 9024, 102 (or 1002) and 902 ae typically alued together. The fire resistant center panel 102 oF 102 has a bottom (not shown), a top 106, & first side 108, 9 second side 110, a first end 112 and a second end 114. The ‘extruded fie resistant border 104 is made up ofa first stile 4402 (lft). second stile 404 (right) first rail 406 (top) and ‘a second ral 408 (bottom), The fst stile 402 (left), second, stile 404 (right), first rail 406 (top) and second rail 408 (bottom) are made of the second fire resistant material having a higher density than the first fre resistant material 0 that socond fie resistant material has holding capacity (eg, fasteners will adhere to the second fire resistant ‘material and remain fixed once installed) and ean be shaped Using an extrusion “The firs stile 402 (lef), second stile 494 (right), frst rail 496 (top) and second rail 408 (Gottom) are ghied or fastened together and to the three panels 9924, 192 (or 1002) and 9026, The first stile 402 (eft) ‘s attached to the first side 108 ofthe thee panels 9024, 102 (or 1002) and 9026 using glve, fasteners or a bonding process. The second stile 404 (right) is attached to the second side 110 ofthe tree panels 902a, 102 (or 1002) and ‘9025 using gue, fasteners ora bonding process. The fis rail 406 (top) is atiached tothe fist end 112 of the three panels ‘9022, 102 (or 1002) and 9026 using glue, fasteners oF a boning process. The second rail 408 (top) i attached to the second end 114 of the three panels 9922, 102 (or 1002) and ‘902 using glue, fasteners or a bonding process. Several ‘examples of the interface between the siles 402, 404, the rails 406, 408, and the fire sistant center pancl 102 are shown in FIGS, 3A-3D, FIG, 10B is a eoss-sectional view ‘of the door core of FIG. 10A. [Note that the cores shown in FIGS, 1-10 and B, and described above may also inelude atop panel attached to the ‘op of the core 100, 200, 300, 400, 500, 600, 700, 80, 900 ‘0 1000, ora bottom panel attached tothe bottom of the core 100, 200, 300, 400, 300, 600, 700, 800, 90 o7 1000, or bots 0 o 14 the top panel and the bottom panel attached to the core 100, 200, 300, 400, 500, 600, 700, 800,900 or 1000. Example of ‘such a configuration is shown in FIGS, 13A and 144. The top pane! of the bottom panel can be a lignocelvlosie substrate, a wood, a wood composite, a medium density fiberboard, a high density fiberboard, 2 particleboard, rmatonite, a fiberglass, a metal, a plastic, @ fie resistant panel, one or more protective layers of a combination thereol: The one or more protective layers ean be a fre resistant material, a blast resistant material a ballistic ress- ‘ant material, a shielding material, a chemical resistant ‘matesal, a biohazard resistant material, a radiation resistant ‘material, a dampening material, 2 grounding material, ins- lating material ar a combination thereof. For example, the ‘one or more protective layers can be one or more gypsom boards, one or more metalic sheets, one or more lead sheets fone oe mare Kevlar sheets, one oF more ceramic shoes, @ layer of urethane foam, a layer of graphite, a wire mesh or 4 combination thereat. Moreover, the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 undr top or bottoms panels can be coated with an intumescent or fire resistant ‘ates Finally note that the rls shown in the figures ea textend to the sides of the door or core such thatthe stiles extend between the top and bottom ral Referring now to FIG. ILA, an exploded perspoctve view offre rated door 1100 in accontance with one embodiment ‘of the present invention is shown. The fie rated door 1100 ‘includes a core 100, 200, 300, 400, 800, 600, 700, 800, 900 ‘or 1000 (Soe FIGS. 1-108 and B and associated dosription or details), a fist docorative panel 1102 and a socond docomtive panel 1104, The fist and second decorative pancl 1102 and 1104 can bea lignocellulosi substrate, a wood, ‘wood composite, a medium density fiberboard, a high den- sity berboard, & particleboard, a masonite, a fberslas, a metal, a plastic, a fire resistant material or a combination thereol. The fist decorative panel 1102 i attached 0 the top ‘of the care 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 using ghue. The second decorative panel 1108 is attached to the bottom of the core 100, 200, 300, 400, 500 {600, 700, 800, 900 oF 1000 using elie. Nove that the gle say have fire resistant properties or contain an intumescent material. The first and secone decorative panels 1102 and 1104 havea slighty lager length and width to accommodate ‘anexterior banding 1106 attached wo each side and end ofthe core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. ‘The exterior handing 1106 ean be a first banding 11062, 3 second banding 11066, a third banding 1106 and a fourth ‘banding 1106d. FIG. 11 shows a cross-sectional view of the fie rated door 1100, FIG. LIC shows a erost-scetional view ofan altemative version of te fre rte! dooe 1100 in ‘which an intumescent banding saterial 1108 can also be disposed between the exterior banding 1106 and the core 100, 200, 300, 400, $00, 600, 700, 800, 900 or 1000, [Now referring to FIG. 12A, an exploded perspective view ‘ofa fre rated door 1200 in accordance with another embodi- ‘ment of the present invention is shown. The fire rated door 1200 includes a core 100, 200,300, 400, $00, 600, 700, 800, 900 oF 1000 (see FIGS. 1-10A and Band associated deserip- tion for details), first devorative pel 1102 and a second decorative panel 1104. The ist and second decorative panel 1102 and 1104 can bea lignocellulosi substrate, 2 woud, 2 ‘wood composite, a medium density fiberboard, a high den- sity fiberboard, a paneleboard, a masonite, a fibers, a ‘etal a plastic, a fire resistant material of a combination ‘thereof. Note that he frst andl second decorative panels 1102 fad 1104 may also have fie resistant properties. The frst ‘ecortive panel ILO2 is attached tothe top of the core 100,US 10,240,089 B2 15 200, 300, 400, 500, 600, 700, 800, 900 oF 1000 using glue. ‘The second decorative panel 1104 is attached t the bottom ‘ofthe core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 using gluc. Note that the gle may have fire resistant properties of conan an intuescent material. The fist and second decorative panels 1102 and 1104 have the same Jength and width asthe core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000. As a result, additonal banding, rails ‘and stiles are not needed, FIG. 128 shows a eoss-setional View of the fire rated door 1200, Referring now 10 FIG, 13, an exploded perspective view ‘fa fire rated door 1300 in accordance with another embod ‘ent of the present invention is shown, The fire rated door 41300 includes a core 100, 200, 300, 400, $00, 600, 70, 800 ‘900 or 1000 sce FIGS. 1-10 and It and associated descrip tion for details, a frst protective panel or layer 1302 (also referred toa a top panel), a frst docorative panel 1102, 2 second protective panel o layer 1304 (also referred to 28 2 bottom panel) aud second decorative panel 1104, The fist 2 protective panel or layer 1302 and the second protective pane] or layer 1304 can be fre resistant material, a blast resistant material, ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material ra Fal, @ giounding material, insulating material or 8 combi nation thereot: For example, the fist protective panel or Jayer 1302 andthe second protective panel or layer 1304 can be one oF more gypsum boards, one or more metallic sheets, ‘one or more lea sheets, one oF more Kevlar sheets, one oF more ceramic sheets, a layer of urethane foam, a layer of raphite, a wire mesh or a combination thereof. A 120 ‘minute fire rated door can be obtains by using a dense fre resistant material, such as second fire resistant material, as the fist and second protective panels or layers 1302 and 1304. The first and second decorative pane! 1102 and 1104 ‘can be a lignocellulosic substeate, wood, 2 wood compos= ite, a medium density berboard, «high density fiberboard, a panicleboaed, a masonite, a fiberglas, a metal, aplastic, 2 fire resistant material or & combination thereof. The fist decorative panel 1102 is attached to the top of the fist protective pane! or layer 1302 using glue. The fist protec- tive panel or layer 1902 is stached to the top ofthe coee 100, 200, 300, 400, 00, 600, 700, 800, 900 oF 1000 using glue ‘The second decorative panel 1104 js attached t the bottom, ‘of the second protective panel or layer 1304 using glue. The second protective panel or layer 1304 is attached 10 the bottom of the core 100, 200, 300, 400, $00, 600, 700, 800 ‘900 oF 1000 using glue. Note thatthe ghie may have fre resistant properties or contain an intumescent material, The first and second decorative panels 1102, 1104 and frst and second protective panels or layers 1302, 1304 have the same Jength and width as the core 100, 200, 300, 400, 300, 600, 700, 800, 90 o- 1000. As a result, additional banding, rails and stiles are not needed, FIG. 13B shows @ cross-sectional View of the fre rated door 1300, FIG. 13C shows a eross- sectional view ofan alternative version ofthe fire rated door 1300 in which the fist and second decorative panels 1102 and 1104 have a slightly larger length and width to-accom- modate an exterior banding 1106 attached to each side and ‘end ofthe core 100, 200, 300, 400, $00, 600, 700, 800, 900, ‘oF 1000, As shovsn in FIG. 11, the exterior banding 1106 ‘canbe a fist banding 11062, sceond banding 1106, «third banding 1106e and fourth banding 1106d. In adiion, aa femative version of the fire mited door 1300 can” be Tabicated in which an iotumesceat banding material 1108 is jon resistant material, a dampening mate- > 16 disposed between the exterior banding 1106 and the core 100, 200, 300, 400, $00, 600, 700, 800, 900 or 1000 (see FIG. 10), [Now referring to FIG. 14A, an exploded perspective view ‘ofa fire rated door 1400 in accordance with another embod ‘ent of the present invention is shown The fire rated door 1400 includes a core 109, 200,300, 400, 500, 600, 700, 800, 900 or 1000 (see FIGS. 1-104 and B and associated deserip- sion for details) ist insulating panel o layer 1402, a frst ecomtive pancl 102, second insulating panel or layer 1404 and a second decorative panel 1104, The fist insulat- ing pane! or layer 1402 and the second protective punel or layer 1404 is made of a corrugated filler (g., cardboard, ce.) having a plurality of voids (eg, honeycomb shapes hexagon shaped, triangular shaped, ete.) filled. with an sulting and/or fire resistant material (eg, berglas, foam, ete). The first and second decorative panel 1102 and 1104 can be a ligpocellulosic substrate, 2 wood, a wood composite, # medium density fiberboard, a high density {Therboar, a particleboard, a masonite. a fiberglass, a met a plastic, a fire resistant material or a combination thereof. ‘The first decorative panel 1102 is atached tothe top of the first insolating pancl of layer 1402 using glue. The first insulting panel or layer 1402 is attached to the top of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 ‘using ghte. The second decorative panel 1104 is attached t0 the bottom of the second insulating panel or layer 1404 using alue, The second insulating panel or layer 1404 is attached ‘o the bottom ofthe core 100, 200,300, 400, $00,600, 700, £800, 900 o¢ 1000 using glue. Note thatthe gle may have fire resistant properties or contain a intumescent material, The first and second decorative panels 1102, 1104 and first and second insulating panels or layers 1402, 1404 have the same Jenuth ancl width as the core 100, 200, 300, 400, $00, 600, 700, 800, 900 or 1000. As a result, additional banding, rails ‘and stiles are not needed. FIG. 148 shows a cross-sectional view of the fre rated door 1400. FIG. L4C shows a cross sectional view of an alternative version of the fire rated door 1400 in which the first and second decorative pancls 1102 ‘and 1104 havea slightly larger length and width to aecom- ‘oat an exterior handing 1106 attached to cach side and end of the core 190, 200, 300, 400, 500, 600, 700, 800, 900 for 1000. As shown in FIG. 11A, the exterior banding 1106 ean bea fist banding 11062, second banding 11060, third banding 1106c and a fourth banding 1106d. In addition, an altemative version of the fire rated door 1400 canbe Tiabricated in which an intumesoeot banding material 1108 is isposed between the exterior banding. 1106 and the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or L000 (soe FIG. NC), Referring now to FIG. 134. an exploded perspective view offre rated door 1500 in accordance with another embed ‘ent of the present invention is shown, The fie rated door 1500 includes a core 100, 200,300, 400, 500, 600, 700, $00, 900 oF 1000 (see FIGS, 1-10 and associated deseription for otails), a frst decorative panol 1102, a second docorative pane! 1104 and four rails 1502. AKemativey, the core 10, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 can be & Single sheet of fire resistant material, including, but-not Jimi to the frst fire resistant material. ‘The back side of lint and second decorative pane! 1102 and 1104 include a notch of eutout 1804 along the fet and right sides that is sized 10 fit each rail 1502, Fach rail 1502 is made of the second fre resistant material or other stable material In ‘one example, the rails havea height of "7c" and width of 1" ‘The first and second decorative panel 1102 and 1104 can be lignocellulosic substrate, 2 wood, a wood composite, aUS 10,240,089 B2 17 medium density Sberboard, a high density fiberboard, 9 particleboard, 2 masonite, a fibemplass, a metal, a plastic, 2 fire resistant material ora combination there Nove that the first and second decorative panels 1102 and 1104 may’ also have fre resistant properties. The first decorative panel 1102 js attached to the op of the core 100, 200, 300, 400, $00, 600, 700, 800, 900 or 1900 or single sheet of fire resistant material using glue. The second decorative panel 1104 is tached tothe bottom of the core 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 or single sheet of fire resistant material using. glue, Note that the ghie may have fire resistant properties or contain an intumescent material, The first and second decorative panels 1102 and 1104 have the same Tength and wih as the core 100, 200, 300, 400, S00 600, 700, 800, 900 or 1900 or single sheet of fire resistant ‘material. As a result, additonal handing, rails and stiles are not needed. FIG. 158 shows a eros-scctional View of the fire ited door 1400, [Now referring to PIG. 16, a low chart ofa method 1600 ‘of manufacturing a door core for a fire rated door in > ‘ocordance with one embodiment ofthe present invention is shown. A fie 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 pane is made ofa fist fie resistant material. A first stile of ‘an extruded fie resistant border is attached tothe first side ‘of the fre resistant center panel in block 1604, wherein the ‘extrude! fire resistant border is made of a second fire resistant material having «higher density than the frst fre resistant material, A second stile of the exteuded fr resistant border is attached to the second side of the fre resistant ‘enter pane! in block 1606. A first rail of the extruded fire Fesistant borders attached to the ist end ofthe fre resistant ‘center panel and the first stile and the second stile of the ‘exude fire resistant border in block 1608, A secoad ral of the extrude fire resistant horde is attached 10 the second ‘enc of the fire resistant center panel andthe first stile and the second silo of the extnided fire resistant border in block 1610. An optional stop may inclde forming a fre rated door by attaching fist decorative and a sovond decorative panel to the top and bottom, respectively, of the fire resistant center panel, the first stile, the second stil, the frst rail and the econ rail of the extruded border in lock 1612. Additional ‘elements can be added as described in reference to FIGS, AL-ISA and B. Another optional step may include coating the fre resistant center panel and the extruded fire resistant border with an intumescent o fie resistant material. Note that the method 1600 can be pecfomed as part of a cone Finuous manufacturing process In one embodiment, a notch is formed inthe first side of the fie resistant center panel, a fire resistant lock block is inserted within the notch and te fre resistant lock block is faces tothe fre resistant center panel and the extruded fire resistant border, wheccin the fie resistant lock block is made of the second fire resistant material. In. another ‘embodiment, the fire resistant center panel includes: (@) 3 fst fire resistant center pane! disposed between the frst side and the second side proximate 10 the first end, wherein the first fre resistant center panel is made of the first fre resistant material; (b) a second fire resistant center panel disposal between the frst side and the second side proxi mate to the second end, wherein the second fire resistant ‘enter panel is made of the frst fire resistant material; and (6) fire resistant insert disposed betwoen and attached t0 the first fre resistant center panel and the second fire resistant center panel, and extending tween and attached to the extruded fire resistant border tthe first side and the 18 second side, wherein the fie resistant material is made ofthe Second fire resistant material. Ia yet another embodiment, a set of male-female connectors are formed in the extruded fire resistant border and the fire resistant center panel. The ‘+ male-female connoctors can be trangular-shapes, curved- shaped, rectangular-shaped, angled, tongue-and-groove, oF a combination thereat Ta anther embodiment, the first fie resistant material is extnided oF molded 10 form the fire resistant center panel, land the second fire resistant material is extruded or molded to form the first stile, the second stile, the frst rail and the sevond mil of the extruded fie resistant border. In yet ‘another embodiment, the fist fire resistant material” is textnided oF molded to form the fie resistant eeater pane, and the second fire resistant material is extruded or molded ‘o form a sheet that is then gang ripped to form ane or more ‘ofthe frst stile, he second stile, the ist rail and the second nil of the extruded fre resistant border. In either embodi- ‘ment the panels, sis and rails may undergo one or more finishing steps (¢g., sanding, trimming, euting, denibbing. ce.) so tha the pisces have the proper smoothness, size and shape: Furthermore, atop panel canbe ataced tothe top ofthe fire resistant center panel and the extruded fire resistant border, or a bottom panel can be attached to the bottom of the fie resistant center panel, or bot the top panel and the bottom panel can be sttachedl to the fire resistant center ‘panel, The top panel or the bottom panel can be a Hignocel- Iulosic substrate, a wood, a wood composite, 2 medium density fiberboard, a high density fiberboard, a panicle- board, a masonite, a fiberglass, a metal, a plastic, one or more protective layers ora combination thereof. The one or ‘ore protective layers can bea fie resistant material Blast resistant material, ballistic resistant material, shielding ‘chemical resistant material, a biohazard resistant ‘material, a radiation resistant material, a dampening mate- rial, a grounding material, insulating material or 2 com nation thereof. For example, the one or more protective layers can he one or more gypsum boards, one or more metalic shoots, one or move lead sheets, ane or more Kevlar sheets, one oF more ceramic sheets a layer of urethane fam, a layer of graphite, a wire mesh or a combination thereof. Referring now to FIG. 17, a low chat of a method 1700 of manuficturing a door core for a fire rated door in faecordance with another embodiment of the preseatinven- ‘ion is shown, An extrided fre resistant border i provided in block 1702. The extrded fire resistant border hos central void and is manufactured by providing a first stile of the extruded fire resistant border, attaching a fist rail ofthe extnded fre resistant border tothe first stile ofthe extraded fire resistant border, attaching a second mil of the extruded fire resistant border to the first stile and attaching a second stile ofthe extraded fire resistant border to the first rail and the send mil ofthe exttided fre resistant border, wherein the extnided fire resistant border is made of a second fre resistant material. The void within the extruded fre resistant border i filed with first fie resistant material that is a lower density than the second fire resistant material to form fire resistant center panel in block 1704, The extruded fire resistant border and fist fie resistant material are baked or ‘ered to set and fx the material in block 1706, Sanding oF other finishing steps may be performed thereafter. An ‘optional step may ineInde forming # fire rated door by fttaching a first decorative and a second decorative panel t0 the top and bottom, respectively, of the extruded fre resi tant border and fire resistant center panel in block 1708 Additonal elements can be added as described in reference 0 oUS 10,240,089 B2 19 0 FIGS. 1-15. An optional step may include coating the fre resistant center patel and the extraded fre resistant border ‘with an intumeseeat offre resistant material. Note that the method 1700 can be performed as part of a continuous manufacturing process In one embodiment, a notch is formed inthe first side of the fie resistant center panel, a fire resistant lock block is inserted within the notch and the fre resistant lock block is 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. In another ‘embodiment, the fre resistant center panel includes: () a first fice resistant center pane! disposed between the frst side ‘and the second side proximate the frst end, wherein the first fire resistant center panel is made of the first fire resistant material; (b) a second fire resistant center panel disposed between the frst side and the second side proxi male to the second end, wherein the second fire resistant ‘enter panel js made ofthe first fie resistant material; and ()a fie resistant insert disposed between aad attached to the fist fre resistant center panel and the second fire resistant center panel, and extending between and attached to the extruded fre resistant border at the fist side and the second sid, wherein the ire resistant material is made ofthe second fire resistant material. In yet another embodiment, & fet of male-female connectors are formed in the extruded fire resistant border and the fire resistant center panel. The male-female connectors can be tiangulaeshaped, curved- shaped, rectangular-shaped, angled, tongue-and-groave, or 8 ‘combination thereo. In another embodiment, the fist fire resistant materials ‘extrude! or mold to form the fire resistant center panel, land the second fire resistant terial is extnce or molded to form the First slike, the second stile, the first rail and the second mil of the extnided fire resistant border. In yet ‘another embodiment, the first fie resistant material is ‘extraded or molded to form the fire resistant center pane, ‘and the second fie resistant material is extruded or molded to form a sheet that is then gang ripped o form ane ar more ‘of the first stile, the second stile, the fist rail an the second, rail of the extrided fie resistant horde. thermore, atop panel can be attached tothe top ofthe fire resistant center pauel and the extruded fire resistant border, ora bortom panel ean be attached to the bottom of the fre resistant center panel, or both the top panel and the bottom panel can be attached to the fire resistant center panel. The top panel or the bottom panel can be # lignocel- Tulosie substrate, a wood, a wood composite, medium density fiberboard, a high density fberboard, a particle. board, masonite a fiberglass, 2 metal, a plist, ane or more protective layers ora combiaation thereof. The one or more protective ayers can bea fire resistant material blast resistant material, ballistic resistant material, a shielding ‘material, a chemical resistant material, a biohazard resistant material, 4 radiation resistant material, a dampening mate Fial, @ giounding material, insulating material or a com! nation thereof. For example, the one or more protective Jayers ean be one or more gypsum boards, one oF more metal sheets, one or more lead sheets, ne or more Kevlar sheets, one or more ceramic sheet, layer of urethane foam, a Layer of graphite, «wire mesh or a combination thereol [Now referring to FIG. 18, a flow chart of method 1800 ‘of manufacturing a fire rated door in accordance with one ‘embodiment ofthe present invention is shown. A door core ‘as shown in FIGS. 1-10 is provided in block 1802. A fist decorative panels attached to atop of the door core in block 1804, anda second decorative panel is attached toa bottom 20 ‘of the door core in block 1806, Additonal elements ean be faded as described in reference to FIGS, MM. “Although preferred embodiments ofthe preseat invention have boon described in detail, it wil be understood by those 5 skill in the art that various modifications can be mado therein without departing from the spirit and scope of the invention as set forth in the appended claims. ‘What is else is 1. A method for manfactoring a fire resistant composite product comprising: ‘mixing gypsum in an amount sufficient provide fire resstanoe wherein the amount i 60 10 9% by weight, fibers in an amount of 1.5 t0 26% by weight, and 9 theology-modifying agent in an amount of 0.5 to He by ‘weight with water, wherein the fibers are substantially homogeneously distributed through the mixture ‘wherein the fibers comprise glas fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers wherein the rheology-moditying agent comprises hhydroxypropoyl_ methyl celluose (HPMC), methyl hiydroxgethy! cellulose (MHFO), hydroxyethyl cel lose (HEC) or carboxymethyl cellulose (CMC); and curing the mixture to foem the fie resistant composite product 2."The method a recited in claim 1, further comprising ing an aggregate in an amount of 10 to 25% by weight into the mixture, wherein the aggregate is substantially homogeneously distbuted through the misture 3. The method as rected in claim 1, futher comprising inixing a stare in an amount of 2 to 7% by weight into the 4, The method as recited in claim 1, further comprising sixing a vermiculite of clay in an amount of Ito 10% by ‘Weight into the mixture, whereia the vermiculite or ela is substantially homogeneously distributed through the mix- ture '8. The method as rected in claim 1, whorwin the glass sihors are in an amount of 1.5 to 52% by weight. 66. The method as recited in claim 1, wherein the glass fibers are in an amount of 2 to 10R% by weight; the Gelulose fibers are in an amount of 2 to 8% by weight the polyvinyl alcohol fers are in an amount of Ito 4% by weight; and the polypropylene fibers are in an amount of 03 wo 4% by Weight 7. The method as recited in claim 1, wherein the mixmare does not include any eement or Hash. 8. The method a recited in claim 1, further comprising ‘molding or extruding the mixture to form a sheet. '9. The method 36 recited in claim 1, further comprising sanding, imming, cutting, denibbing or gang ripping the fire resistant composite product. 10, Amelbod for manufacturing a fre resistant composite product comprising ‘mixing gypsum in an amount sufficient to provide fre resistance wherein the amount is 60 to 85% by weight, fibers in an amount of 15 t 5% by weight, an ‘aggregate in an amount of 10 t0 25% by weight, 2 Starch in an amount of 2 to 7% by weight and a rhoology-modifying agent in an amount of 0.5 to 4% by ‘weight with water, wherein the fibers and the aggregate fare substantially homogensously distributed through the mixture and the fibers comprise glass fibers, cell- lose fibers, polyvinyl aleohal fibers and polypropylene thers curing the mixture to form the fie resistant composite Product. 0 oUS 10,240,089 B2 2 11, The method as recited in claim 10, mixing a vermicw- Jie of clay in an amount of 1 to 10% by weight iato the mixture, wherein the vermiculite or elay #8 substantially hhomogencously distributed through the mixture 12. The method as recited in claim 10, wherein the bers have ® diameter of 6 mm to 25 mm, 13. The method as recited in claim 10, wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHC), hydroxyethyl cellulose (HEC) or carboxymethy! cellulose (CMC) 14. The method as recited in claim 10, wherein the aggregate have an average particle diameter of 1 4 mm. 18. The method as recited in claim 10, wherein the mixture does not include any cement or flyash 16. The method as recited in claim 10, furder comprising ‘molding or extruding the mixture to form a sheet 17. The method as rected in claim 10, further comprising sanding, trimming, cutting, denibbing or gang ripping the fire resistant composite product. 18, A method for manufacturing a fire resistant composite product comprising: : ng gypsum in sn amount sufficient to provide fire resistance wherein the amount is 70 10 90% by weight floss fibers in an amount of 2 to 10% by weight, 2 cellulose fibers in an amount of 2 10 8% by weight, polyvinyl aleobol fibers in an amount of 1 to 4% by ‘weight, polypropylene fibers in an amount of 0.310 4% by weight, and a rhoology-modifying agent in an amount of 0.5 to 6% by weight with water, wherein the glass fibers, celilose fibers, polyvinyl aleobo fibers land polypropylene fibers are substantially homoge- ously distributed through the mixture: ceuring the mixture to form the fie resistant composite 19, The method gs recited in clsim 18, wherein the fibers have a diameter of 6 mm to 25 mn, 20, The method! as recited in claim 18, wherein the sheology-modifying agent comprises hydroxypropoyl ‘ethyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) oF earboxymethy] cellulose (CMC), 21. The method as recited in claim 18, wherein the mixture dees not include any eement or fyash, 22. The method as recited in claim 18, futher comprising molding or extrading the mixture to form a shee. 23, The method as recited in claim 18, further comprising sanding, trimming, cutting, denibbing or gang ripping the fire resistant composite product.