Gypsum composites used in fire resistant building components

• US 10,240,089 B2
• Filed: 08/08/2016
• Issued: 03/26/2019
• Est. Priority Date: 06/29/2012
• Status: Active Grant

• Current Assignee: The Intellectual Gorilla GmbH
• Original Assignee: The Intellectual Gorilla GmbH
• Inventors: Daniels, Evan R., Newton, Jonathan
• Primary Examiner(s): Thompson, Camie S
• Application Number:
  US15/230,774
• Publication Number:
  US 20160340587A1
• Time in Patent Office: 960 Days
• Field of Search: 106772, 106650, 106711, 106780, 106779, 524423, 524 35, 524 43, 524 44, 524 5, 5278411, 5278313
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 16/0641 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 2111/1037 Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
• CPC Class Codes: C04B 2111/105 Alumina-free or very low alumina-content materials
• CPC Class Codes: C04B 2111/1056 Silica-free or very low silica-content materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C09K 21/02 Inorganic materials
• CPC Class Codes: E04B 1/941 Building elements specially adapted therefor
• CPC Class Codes: E04B 1/942 slab-shaped
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 2/388 with a frame of other materials, e.g. fibres, plastics
• CPC Class Codes: E06B 2003/704 : of mineral material which is not further specified
• CPC Class Codes: E06B 2003/7042 : with a fire retardant layer
• CPC Class Codes: E06B 2003/7049 : Specific panel characteristics
• CPC Class Codes: E06B 2003/7051 : of layered construction involving different materials
• CPC Class Codes: E06B 3/7015 : characterised by the filling between two external panels fireproof doors E06B5/16; noise insulating doors E06B5/20
• CPC Class Codes: E06B 3/74 : with wooden panels or frame E06B3/721, E06B3/725 and E06B3/76 take precedence
• CPC Class Codes: E06B 3/76 : with metal panels E06B3/721 - E06B3/725 take precedence
• CPC Class Codes: E06B 3/78 : with panels of plastics E06B3/721 - E06B3/725 take precedence
• CPC Class Codes: E06B 3/822 : with an internal foursided frame
• CPC Class Codes: E06B 5/16 : Fireproof doors or similar closures; Adaptations of fixed constructions therefor
• CPC Class Codes: E06B 5/164 : Sealing arrangements between the door or window and its frame, e.g. intumescent seals specially adapted therefor
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/232 : Encased layer derived from inorganic settable ingredient

Abstract

A composite product includes gypsum in an amount of 60 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.

Claims

1. A method for manufacturing a fire resistant composite product comprising:

mixing gypsum in an amount sufficient to provide fire resistance wherein the amount is 60 to 90% by weight, fibers in an amount of 1.5 to 26% by weight, and a rheology-modifying agent in an amount of 0.5 to 6% by weight with water, wherein the fibers are substantially homogeneously distributed through the mixture;

wherein the fibers comprise glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers;

wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC); and

curing the mixture to form the fire resistant composite product.

2. The method as recited in claim 1, further comprising mixing an aggregate in an amount of 10 to 25% by weight into the mixture, wherein the aggregate is substantially homogeneously distributed through the mixture.

3. The method as recited in claim 1, further comprising mixing a starch in an amount of 2 to 7% by weight into the mixture.

4. The method as recited in claim 1, further comprising mixing a vermiculite or clay in an amount of 1 to 10% by weight into the mixture, wherein the vermiculite or clay is substantially homogeneously distributed through the mixture.

5. The method as recited in claim 1, wherein the glass fibers are in an amount of 1.5 to 5% by weight.

6. The method as recited in claim 1, wherein:

the glass fibers are in an amount of 2 to 10% by weight;

the cellulose fibers are in an amount of 2 to 8% by weight;

the polyvinyl alcohol fibers are in an amount of 1 to 4% by weight; and

the polypropylene fibers are in an amount of 0.3 to 4% by weight.

7. The method as recited in claim 1, wherein the mixture does not include any cement or flyash.

8. The method as recited in claim 1, further comprising molding or extruding the mixture to form a sheet.

9. The method as recited in claim 1, further comprising sanding, trimming, cutting, denibbing or gang ripping the fire resistant composite product.

10. A method for manufacturing a fire resistant composite product comprising:

mixing gypsum in an amount sufficient to provide fire resistance wherein the amount is 60 to 85% by weight, fibers in an amount of 1.5 to 5% by weight, an aggregate in an amount of 10 to 25% by weight, a 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 with water, wherein the fibers and the aggregate are substantially homogeneously distributed through the mixture and the fibers comprise glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers;

curing the mixture to form the fire resistant composite product.

11. The method as recited in claim 10, mixing a vermiculite or clay in an amount of 1 to 10% by weight into the mixture, wherein the vermiculite or clay is substantially homogeneously distributed through the mixture.

12. The method as recited in claim 10, wherein the fibers have a 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 (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC).

14. The method as recited in claim 10, wherein the aggregate have an average particle diameter of 1 to 4 mm.

15. 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, further comprising molding or extruding the mixture to form a sheet.

17. The method as recited 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:

mixing gypsum in an amount sufficient to provide fire resistance wherein the amount is 70 to 90% by weight, glass fibers in an amount of 2 to 10% by weight, cellulose fibers in an amount of 2 to 8% by weight, polyvinyl alcohol fibers in an amount of 1 to 4% by weight, polypropylene fibers in an amount of 0.3 to 4% by weight, and a rheology-modifying agent in an amount of 0.5 to 6% by weight with water, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers are substantially homogeneously distributed through the mixture;

curing the mixture to form the fire resistant composite product.

19. The method as recited in claim 18, wherein the fibers have a diameter of 6 mm to 25 mm.

20. The method as recited in claim 18, wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC).

21. The method as recited in claim 18, wherein the mixture does not include any cement or flyash.

22. The method as recited in claim 18, further comprising molding or extruding the mixture to form a sheet.

23. The method as recited in claim 18, further comprising sanding, trimming, cutting, denibbing or gang ripping the fire resistant composite product.