Fire-resistant members containing gypsum fiberboard

• US 5,601,888 A
• Filed: 02/14/1995
• Issued: 02/11/1997
• Est. Priority Date: 02/14/1995
• Status: Expired due to Term

• Current Assignee: Georgia-Pacific Gypsum LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia-Pacific Corporation
• Inventors: Fowler, George F.
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): WEISBERGER, RICHARD C
• Application Number:
  US08/388,018
• Time in Patent Office: 728 Days
• Field of Search: 52/309.2, 52/201, 52/171.3, 52/204.1, 428/34, 428/68, 428/70, 428/428, 428/921
• US Class Current: 428/34
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 14/38 Fibrous materials; Whiskers
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 2103/0091 Organic co-binders for mineral binder compositions
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00655 Profiles
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2111/30 Nailable or sawable materials
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: E04B 2/7411 Details for fire protection
• CPC Class Codes: E06B 2003/7059 Specific frame characteristics
• CPC Class Codes: E06B 3/5892 Fixing of window panes in openings in door leaves
• CPC Class Codes: E06B 5/162 Fireproof doors having windows or other openings, e.g. for permitting ventilation or escape
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/232 Encased layer derived from inorganic settable ingredient

Abstract

Fire-resistant structures are provided having at least a 20 minute ASTM E-152 fire test rating. The structures include glass partition walls having framing members formed from a gypsum-containing composition having a density of at least about 60 lbs/ft³, a flexural strength of at least 30 lbs ( 1/2 inch thick material), and a screw-holding capacity of at least about 400 lbs. The gypsum-containing composition further contains a substantially uniform distribution of solids including about 65 wt.% to about 90 wt.% set gypsum dihydrate, about 7 wt.% to about 30 wt.% paper fiber, and about 1.5 wt.% to about 35 wt.% of one or more performance boosters selected from inorganic fiber, clay, vermiculite, and binder polymer.

Claims

1. A method of preparing an improved structure of the type having a glass panel supported by at least first and second framing members and having at least a 20 minute ASTM E-152 fire test rating, characterized by the steps comprising:

attaching said first framing member to said second framing member to provide support for said glass panel, at least one of said framing members comprising a gypsum-containing fiberboard composition having a density of at least about 60 lbs/ft³, a flexural strength of at least about 30 lbs (1/2 inch thick material), and a screw-holding capacity of at least about 400 lbs, said composition containing a substantially uniform distribution of solids including about 65 wt.% to about 97 wt.% set gypsum dihydrate and about 1.5 wt.% to about 30 wt.% paper fiber.

2. The method of claim 1 wherein at least one of said gypsum-containing framing members is a machined framing member.

3. The method of claim 1 wherein said composition comprises about 75 wt.% to about 95 wt.% set gypsum dihydrate, about 5 wt.% to about 15 wt.% paper fiber, and about 1.5 wt.% to about 35 wt.% of performance boosters selected from inorganic fiber, clay, vermiculite, binder polymer and mixtures of these.

4. The method of claim 1 wherein said structure has at least a 20 minute ASTM E-152 fire test rating.

5. The method of claim 1 wherein said paper fiber comprises recycled scrap paper.

6. The method of claim 1 wherein said composition comprises about 1 wt.% to about 3 wt.% binder polymer.

7. The method of claim 1 wherein said binder polymer comprises at least one of:

poly(vinyl acetate), poly acrylate, and poly(vinyl alcohol).

8. The method of claim 1 wherein said composition comprises from about 88 wt.% to about 92 wt.% set gypsum dihydrate, about 5 wt.% to about 10 wt.% paper fiber, from about 1 wt.% to about 3 wt.% inorganic fiber, and from about 0.5 to about 2 wt.% vermiculite.

9. The method of claim 1 herein said composition has a density of at least about 80 lbs/ft³ and a screw-holding capacity of at least about 500 lbs.

10. The method of claim 8 wherein said inorganic fiber comprises glass textile fiber.

11. The method of claim 1 wherein at least on of said framing members has a decorative wood veneer adhered to at least one surface thereof.

12. The method of claim 1 further comprising gasket material between said glass panel and at least one of said gypsum-containing framing member.

13. The method of claim 1 wherein said gasket material is a nonintumescent material.

14. An improved structure comprising:

(a) a glass panel; and

(b) framing members for framing and supporting said glass panel, at least one of said framing member comprising a gypsum-based framing member having a density of at least about 60 lbs/ft³.

15. The structure of claim 14 wherein said fiberboard framing member comprises a composition containing a major proportion of set gypsum dihydrate and a minor proportion of cellulosic fibers.

16. The structure of claim 14 wherein said fiberboard framing member comprises a composition containing a substantially uniform distribution of solids including about 65 wt.% to about 97 wt.% set gypsum dihydrate and about 1.5 wt.% to about 30 wt.% paper fiber.

17. The structure of claim 16 wherein said fiberboard framing member composition further comprises about 1.5 wt.% to about 35 wt.% of performance booster selected from inorganic fiber, clay, vermiculite, binder polymer, and combinations of these.

18. The structure of claim 16 wherein said fiberboard framing member has a screw-holding capacity of at least about 400 lbs.

19. The structure of claim 16 wherein said framing member composition comprises about 75 wt.% to about 95 wt.% set gypsum dihydrate, about 5 wt.% to about 15 wt.% paper fiber, and about 1.5 wt.% to about 35 wt.% of performance boosters selected from inorganic fiber, clay, vermiculite, binder polymer and mixtures of these.

20. The structure of claim 14 having at least a 20 minute ASTM E-152 fire test rating.

21. The structure of claim 19 wherein said paper fiber comprises recycled scrap paper.

22. The structure of claim 17 wherein said composition comprises about 1 wt.% to about 3 wt.% binder polymer.

23. The structure of claim 22 wherein said binder polymer comprises at least one of:

poly(vinyl acetate), poly acrylate, and poly(vinyl alcohol).

24. The structure of claim 16 wherein said composition comprises from about 88 wt.% to about 92 wt.% set gypsum dihydrate, about 5 wt.% to about 10 wt.% paper fiber, from about 1 wt.% to about 3 wt.% inorganic fiber, and from about 0.5 to about 2 wt.% vermiculite.

25. The structure of claim 14 wherein said fiberboard framing member has a density of at least about 80 lbs/ft³ and a screw-holding capacity of at least about 500 lbs.

26. The structure of claim 24 wherein said inorganic fiber comprises glass textile fiber.

27. The structure of claim 14 wherein said fiberboard framing member has a decorative wood veneer adhered to at least one surface thereof.

28. The structure of claim 14 further comprising gasket material between said glass panel and said fiberboard framing member.

29. The structure of claim 28 wherein said gasket material is a nonintumescent material.