Gypsum composites used in fire resistant building components

• US 10,315,386 B2
• Filed: 06/27/2016
• Issued: 06/11/2019
• 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:
  US15/193,274
• Publication Number:
  US 20160303826A1
• Time in Patent Office: 1,079 Days
• Field of Search: 106 1811, 428220, 524423, 5278411, 5278313, 527841, 156 42
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/04 comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/04 comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/042; next to a bituminous or tarry layer B32B11/042; next to a water setting substance layer B32B13/10; next to a metal layer B32B15/10; next to a glass layer B32B17/062; next to a layer formed of natural mineral fibres or particles B32B19/042; next to a cellulosic plastic layer B32B23/044
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 3/14 characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 9/005 comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• 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 20/002 : Hollow or porous granular materials
• CPC Class Codes: C04B 20/0068 : Composite fibres, e.g. fibres with a core and sheath of different material
• CPC Class Codes: C04B 2103/0079 : Rheology influencing agents
• CPC Class Codes: C04B 2111/0062 : Gypsum-paper board like 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: E04B 1/94 : against fire fire protection of partitions E04B2/7403, E04B2/7409; supporting constructions for ceilings having the capability of expansion in case of fire E04B9/08; fire-fighting A62C, e.g. fire prevention or containment A62C2/00; impregnation of wood or similar materials B27K; fireproof paints C09D5/18; fireproofing materials C09K21/00; flame-resistant papers D21H5/0002; coverings or linings, e.g. for walls or ceilings, in general E04F13/00; fireproof doors E06B5/16; firebreak devices for pipes or the like passing through walls F16L5/04; protection of pipes by means of non-inflammable material F16L57/04
• CPC Class Codes: E04B 1/942 : slab-shaped
• CPC Class Codes: E06B 2003/7019 : of corrugated type
• CPC Class Codes: E06B 2003/7032 : of non-vegetal fibrous material, e.g. glass or rock wool
• CPC Class Codes: E06B 2003/7036 : of plaster
• CPC Class Codes: E06B 2003/7038 : made from a slurry
• CPC Class Codes: E06B 2003/7042 : with a fire retardant layer
• CPC Class Codes: E06B 2003/7051 : of layered construction involving different materials
• CPC Class Codes: E06B 2003/7059 : Specific frame characteristics
• 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 3/822 : with an internal foursided frame
• CPC Class Codes: E06B 5/161 : Profile members therefor
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

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.

Claims

1. A fire resistant composite material comprising:

gypsum in an amount sufficient to provide fire resistance, wherein the amount is 60 to 90% by weight;

glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers substantially homogeneously distributed through the composite;

a rheology-modifying agent; and

wherein the fire resistant composite material does not include any cement or flyash.

2. The fire resistant composite material as recited in claim 1, wherein:

the fire resistant composite material is caused or allowed to cure to form a cured fire resistant composite material; and

the cured fire resistant composite material is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel, wherein the fire resistant component is selected from a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, and a door insert.

3. The fire resistant composite material as recited in claim 2, wherein the fire resistant component material is extruded prior to being cured.

4. The fire resistant composite material as recited in claim 2, wherein the cured fire resistant component material has a cross-sectional thickness of 0.125 inches to 2 inches, a width of 1 inch to 4 feet and a length of 3 to 10 feet.

5. The fire resistant composite material as recited in claim 1, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers are in an amount of 1.5 to 26% by weight.

6. The fire resistant composite material as recited in claim 1, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers are in an amount of 1.5 to 5% by weight.

7. The fire resistant composite material as recited in claim 1, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers have a diameter of 6 mm to 25 mm.

8. The fire resistant composite material as recited in claim 1, wherein the rheology-modifying agent is in an amount of 0.5 to 6% by weight.

9. The fire resistant composite material as recited in claim 1, wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC).

10. The fire resistant composite material as recited in claim 1, further comprising an aggregate substantially homogeneously distributed through the fire resistant composite material.

11. The fire resistant composite material as recited in claim 10, wherein the aggregate is in an amount of 10 to 25% by weight.

12. The fire resistant composite material as recited in claim 10, wherein the aggregate has an average particle diameter of 1 to 4 mm.

13. The fire resistant composite material as recited in claim 1, further comprising a vermiculite or clay.

14. The fire resistant composite material as recited in claim 13, wherein the vermiculite or clay is in an amount of 0 to 10% by weight.

15. The fire resistant composite material as recited in claim 1, further comprising a starch in an amount of 2 to 7% by weight.

16. The fire resistant composite material as recited in claim 1, wherein the glass fibers are in an amount of 1.5 to 5% by weight.

17. The fire resistant composite material 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.

18. The fire resistant composite material as recited in claim 1, wherein the glass fibers are in an amount of 1.5 to 5% by weight.

19. A fire resistant composite material consisting essentially of:

gypsum in an amount sufficient to provide fire resistance;

glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers substantially homogeneously distributed through the composite;

a rheology-modifying agent; and

wherein the fire resistant composite material does not include any cement or flyash.

20. A fire resistant composite material comprising:

gypsum in an amount sufficient to provide fire resistance, wherein the amount is 60 to 90% by weight;

glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers substantially homogeneously distributed through the composite;

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

wherein the fire resistant composite material does not include any cement or flyash.

21. The fire resistant composite material as recited in claim 20, wherein:

the fire resistant composite material is caused or allowed to cure to form a cured fire resistant composite material; and

the cured fire resistant composite material is a fire resistant component used in a fire-rated door core, a fire-rated door or a fire-rated building panel, wherein the fire resistant component is selected from a building panel, a door panel, a door core, a door rail, a door stile, a door lock block, a door border, and a door insert.

22. The fire resistant composite material as recited in claim 21, wherein the fire resistant component material is extruded prior to being cured.

23. The fire resistant composite material as recited in claim 21, wherein the cured fire resistant component material has a cross-sectional thickness of 0.125 inches to 2 inches, a width of 1 inch to 4 feet and a length of 3 to 10 feet.

24. The fire resistant composite material as recited in claim 20, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers are in an amount of 1.5 to 26% by weight.

25. The fire resistant composite material as recited in claim 20, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers are in an amount of 1.5 to 5% by weight.

26. The fire resistant composite material as recited in claim 20, wherein the glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers have a diameter of 6 mm to 25 mm.

27. The fire resistant composite material as recited in claim 20, wherein the rheology-modifying agent is in an amount of 0.5 to 6% by weight.

28. The fire resistant composite material as recited in claim 20, further comprising an aggregate substantially homogeneously distributed through the fire resistant composite material.

29. The fire resistant composite material as recited in claim 28, wherein the aggregate is in an amount of 10 to 25% by weight.

30. The fire resistant composite material as recited in claim 28, wherein the aggregate has an average particle diameter of 1 to 4 mm.

31. The fire resistant composite material as recited in claim 20, further comprising a vermiculite or clay.

32. The fire resistant composite material as recited in claim 31, wherein the vermiculite or clay is in an amount of 0 to 10% by weight.

33. The fire resistant composite material as recited in claim 20, further comprising a starch in an amount of 2 to 7% by weight.

34. The fire resistant composite material as recited in claim 20, 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.

35. A fire resistant composite material consisting essentially of:

gypsum in an amount sufficient to provide fire resistance;

glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers substantially homogeneously distributed through the composite;

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

wherein the fire resistant composite material does not include any cement or flyash.