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The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resis

The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resistant material, lead sheeting, steel or Kevlar) can be added between the door panels for various purposes. Splines, stiles or sticks are inserted in longitudinal channels in the door panels to provide assistance in aligning the door panels and greater hardware holding strength. An intumescent banding material concealed by a banding material around the perimeter of the door seals the door within its frame during a fire. The door design and the automated manufacturing process provide greater design choice, reduced cost and faster fabrication.

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What is claimed is: 1. A fire rated door comprising: a first routable door-sized panel; a second routable door-sized panel; wherein a back of the first routable door-sized panel is attached directly to a back of the second routable door-sized panel using an adhesive; two longitudinal interior chann

What is claimed is: 1. A fire rated door comprising: a first routable door-sized panel; a second routable door-sized panel; wherein a back of the first routable door-sized panel is attached directly to a back of the second routable door-sized panel using an adhesive; two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel; a spline disposed within each formed longitudinal interior channel; a perimeter channel cut in each side of the door; an intumescent banding material disposed within each perimeter channel; an exterior banding disposed within each perimeter channel to conceal the intumescent banding material; and wherein the fire rating for the door is achieved without a mineral core disposed between the first routable door-sized panel and the second routable door sized panel by (a) the intumescent banding material and (b) one or more of the following (i) the adhesive is fire resistant and (ii) the first routable door-sized panel and the second routable door-sized panel contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 2. The door as recited in claim 1, wherein the first routable door-sized panel and the second routable door-sized panel comprise a lignocellulosic substrate, a wood, a wood composite, a medium density fiberboard or a combination thereof. 3. The door as recited in claim 1, further comprising one or more protective layers disposed within a large interior channel cut into the back of the first routable door-sized panel and/or the back of the second routable door-sized panel between the splines. 4. The door as recited in claim 3, wherein the one or more protective layers comprise an additional fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a radiation resistant material, a dampening material, a grounding material or a combination thereof. 5. The door as recited in claim 3, wherein the one or more protective layers comprise one or more gypsum boards, one or more metallic sheets, one or more lead sheets, one or more Kevlar sheets, one or more ceramic sheets, a layer of urethane foam, a layer of graphite, a wire mesh or a combination thereof. 6. The door as recited in claim 3, wherein the one or more protective layers contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 7. The door as recited in claim 1, wherein the perimeter channel along the longitudinal sides of the door extend to the spline. 8. The door as recited in claim 1, further comprising a data device containing production data embedded within the door. 9. The door as recited in claim 8, wherein the production data comprises a date that the door was manufactured, a time that the door was manufactured, an order number, a purchase number, a product identifier, a purchaser identifier, a shift identifier, a personnel identifier, a machine line identifier, one or more specifications for the door, a list of hardware for the door, a size of the door, a style of the door, a routing design identifier, a parts list, an options identifier, a special features identifier, an assembly program or a combination thereof. 10. The door as recited in claim 1, wherein the splines contain an intumescent or fire resistant material, or are coated with an intumescent or fire resistant material. 11. A fire rated door comprising: a first routable door-sized panel; a second routable door-sized panel; two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel; a large interior channel cut into the back of the first routable door-sized panel and/or the back of the second routable door-sized panel between the two longitudinal interior channels; a spline disposed within each formed longitudinal interior channel; a perimeter channel cut in each side of the door; an intumescent banding material disposed within each perimeter channel; an exterior banding disposed within each perimeter channel to conceal the intumescent banding material; one or more protective layers disposed within the large interior channel; wherein the back of the first routable door-sized panel, the back of the second routable door-sized panel and the one or more protective layers are attached to one another using an adhesive; a data device containing production data embedded within the door; and wherein the fire rating for the door is achieved by (a) the intumescent banding material and (b) one or more of the following (i) the adhesive is fire resistant, (ii) the one or more protective layers and (iii) the first routable door-sized panel and the second routable door-sized panel contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material. 12. The door as recited in claim 11, wherein the one or more protective layers comprise a fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a dampening material, a grounding material or a combination thereof. 13. The door as recited in claim 11, wherein the perimeter channel along the longitudinal sides of the door extend to the spline. 14. A fire rated door comprising: one or more protective layers disposed within a large interior channel cut into a back of a first routable medium density fiberboard door-sized panel and/or a back of a second routable medium density fiberboard door-sized panel, wherein the protective layers are coated with an intumescent material; two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel; a spline disposed within each formed interior channel wherein each spline is coated with the intumescent material; a perimeter channel cut in each side of the door; an intumescent banding material disposed within each perimeter channel; an exterior banding disposed within each perimeter channel to conceal the intumescent banding material; wherein the back of the first routable door-sized panel, the back of the second routable door-sized panel and the one or more protective layers are attached to one another using an adhesive; and wherein the fire rating for the door is achieved by (a) the intumescent banding material and (b) the intumescent material coating the protective layers. 15. The door as recited in claim 14, wherein the one or more protective layers comprise an additional fire resistant material, a blast resistant material, a ballistic resistant material, a shielding material, a chemical resistant material, a biohazard resistant material, a dampening material, a grounding material or a combination thereof. 16. The door as recited in claim 14, wherein the perimeter channel along the longitudinal sides of the door extend to the spline. 17. The door as recited in claim 14, further comprising a data device containing production data embedded within the door. 18. The door as recited in claim 14, wherein: the first routable door-sized panel and the second routable door-sized panel contain an intumescent or fire resistant material, or are coated with the intumescent material or fire resistant material; or the adhesive is fire resistant. 19. A fire rated door comprising: a first routable door-sized panel; a second routable door-sized panel; wherein a back of the first routable door-sized panel is attached directly to a back of the second routable door-sized panel using a fire resistant adhesive; two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel; a spline disposed within each formed longitudinal interior channel; and wherein the fire rating for the door is achieved by the fire resistant adhesive without a mineral core disposed between the first routable door-sized panel and the second routable door-sized panel. 20. The door as recited in claim 19, wherein each door-sized panel has a fire resistant coating.