The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

A core for a fire rated door includes a fire resistant center panel and an extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made of a first fire resistant material. The extruded fire resistant border is attached to the first side, the second side, the first end and the second end of the fire resistant center panel. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.

The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

A composite product includes gypsum in an amount of 70 to 90% by weight, fibers in an amount of 1.5 to 26% by weight substantially homogeneously distributed through the composite, and a rheology-modifying agent in an amount of 0.5 to 6% by weight. The composite is caused or allowed to cure to form a cured composite. The cured composite is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel. The fire resistant component may include a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, or a door insert.

A fire rated door includes a core, a first decorative panel and a second decorative panel. The core includes: (a) a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material, and (b) an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material. The first decorative panel is attached to the top of the fire resistant center panel and the extruded fire resistant border. The second decorative panel is attached to the bottom of the fire resistant center panel and the extruded fire resistant border.

A hollow core door apparatus for preventing the build up of pressure in a room includes an inside door skin and an outside door skin, and the door skins include openings through which air flows. A center panel is disposed between and spaced apart from the skins. The center panel has an outer perimeter defined by notches through which air flows. Tabs between the notches are used to secure the center panel to the inside and outside door skins. Air flow from the room is through the opening in the inside skin, around the outer perimeter of the panel, and outwardly from the door and room through the outside skin in a non-linear manner. Air flow is controlled by a plurality of movable panels disposed adjacent to the outer perimeter of the center panel. Sensor elements for sensing desired information and for providing output signals, including signals for actuating the movable panels, are included.

Hollow core door apparatus for preventing the build up of pressure in a room includes an inside door skin and an outside door skin, and the door skins include openings through which air flows. A center panel is disposed between and spaced apart from the skins. The center panel has an outer perimeter defined by notches through which air flows. Tabs between the notches are used to secure the center panel to the inside and outside door skins. Air flow from the room is through the opening in the inside skin, around the outer perimeter of the panel, and outwardly from the door and room through the outside skin in a non-linear manner. Air flow is controlled by a plurality of movable panels disposed adjacent to the outer perimeter of the center panel. Sensor elements for detecting aspects of the indoor environment and for providing output signals, including signals for actuating the movable panels, are included. A method of making the door follows the structural elements defined above.

A fire rated door includes a core, a first decorative panel and a second decorative panel. The core includes: (a) a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material, and (b) an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material. The first decorative panel is attached to the top of the fire resistant center panel and the extruded fire resistant border. The second decorative panel is attached to the bottom of the fire resistant center panel and the extruded fire resistant border.