System, Method and Apparatus for Producing Fire Rated Doors

A fire rated door comprising:

• a first routable door panel attached to a second routable door panel, each door panel having two opposing longitudinal interior channels and the attached door panels having a perimeter channel;
• a spline disposed within each interior channel;
• an intumescent banding material and an exterior banding to conceal the intumescent banding material disposed within the perimeter channel;
• one or more protective layers disposed between the first routable door panel and the second routable door panel;
• and
• a data device containing production data embedded within the door.

A fire rated door comprising:

• one or more protective layers disposed between a first routable medium density fiberboard door panel and a second routable medium density fiberboard door panel, wherein the protective layers are coated with an intumescent material, each door panel has two opposing longitudinal interior channels, and the attached door panels have a perimeter channel;
• a spline disposed within each interior channel wherein each spline is coated with the intumescent material;
• and
• an intumescent banding material and an exterior banding to conceal the intumescent banding material disposed within the perimeter channel.

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

• cutting two longitudinal interior channels into a back side of a door panel;
• assembling a door slab by inserting a spline in each longitudinal interior channel of a first door panel, attaching a second door panel to the splines and the first door panel using an adhesive and applying pressure to the door slab to bond the splines and the door panels together;
• cutting a perimeter channel in the sides of the door slab;
• inserting an intumescent banding material and an exterior banding to conceal the intumescent banding material within the perimeter channel;
• routing a specified design into each panel of the door slab;
• applying one or more primer coats to the door slab;
• and
• machining the door slab to receive a set of hinges and lockset hardware.

A computer program embodied on a computer readable medium to control a set of machines to manufacture a fire rated door comprising:

• a code segment for cutting two longitudinal interior channels into a back side of a door panel;
• a code segment for assembling a door slab by inserting a spline in each longitudinal interior channel of a first door panel, attaching a second door panel to the splines and first door panel using an adhesive and applying pressure to door slab to bond the splines and door panels together;
• a code segment for cutting a perimeter channel in the sides of the door slab;
• a code segment for inserting an intumescent banding material and an exterior banding to conceal the intumescent banding material within the perimeter channel;
• a code segment for routing a specified design into each panel of the door slab;
• a code segment for applying one or more primer coats to the door slab;
• and
• a code segment for machining the door slab to receive a set of hinges and lockset hardware.

A manufacturing line to produce fire rated doors comprising:

• a first set of machines to cut two longitudinal interior channels into a back side of a door panel;
• a second set of machines to assemble a door slab by inserting a spline in each longitudinal interior channel of a first door panel, attaching a second door panel to the splines and first door panel using an adhesive and applying pressure to door slab to bond the splines and door panels together;
• a third set of machines to cut a perimeter channel in the sides of the door slab, and insert an intumescent banding material and an exterior banding to conceal the intumescent banding material within the perimeter channel;
• a fourth set of machines to route a specified design into each panel of the door slab;
• a fifth set of machines to apply one or more primer coats to the door slab;
• a sixth set of machines to machine the door slab to receive a set of hinges and lockset hardware;
• and
• one or more conveyors interconnecting the machines to move the door slabs.