Gypsum composites used in fire resistant building components

• US 8,915,033 B2
• Filed: 09/11/2012
• Issued: 12/23/2014
• Est. Priority Date: 06/29/2012
• Status: Active Grant

• Current Assignee: The Intellectual Gorilla GmbH
• Original Assignee: Intellectual Gorilla B.V.
• Inventors: Daniels, Evan R., Newton, Jonathan
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): Agudelo, Paola
• Application Number:
  US13/610,542
• Publication Number:
  US 20140000196A1
• Time in Patent Office: 833 Days
• Field of Search: 524/55, 522/32, 524/56, 525/49, 523/091.2
• US Class Current: 52/232
• 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 core for a fire rated door comprising:

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 comprising 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 substantially homogeneously distributed through the composite, an aggregate in an amount of 10 to 25% by weight substantially homogeneously distributed through the composite, 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; and

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 comprising 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 substantially homogeneously distributed through the composite, cellulose fibers in an amount of 2 to 8% by weight substantially homogeneously distributed through the composite, polyvinyl alcohol fibers in an amount of 1 to 4% by weight substantially homogeneously distributed through the composite, polypropylene fibers in an amount of 0.3 to 4% by weight substantially homogeneously distributed through the composite, and a rheology-modifying agent in an amount of 0.5 to 6% by weight.

2. The core as recited in claim 1, wherein the first fire resistant material further comprises a vermiculite or clay in an amount of 1 to 10% by weight substantially homogeneously distributed through the composite.

3. The core as recited in claim 1, further comprising:

a notch in the first side of the fire resistant center panel; and

a fire resistant lock block disposed within the notch and attached to the fire resistant center panel and the extruded fire resistant border, wherein the fire resistant lock block is made of the second fire resistant material.

4. The core as recited in claim 1, wherein the extruded fire resistant border is attached to the fire resistant center panel with a set of male-female connectors formed in the extruded fire resistant border and the fire resistant center panel.

5. The core as recited in claim 4, wherein the male-female connectors are triangular-shaped, curved-shaped, rectangular-shaped, angled, tongue-and-groove, or a combination thereof.

6. The core as recited in claim 4, further comprising a top panel attached to the top of the fire resistant center panel and the extruded fire resistant border, or a bottom panel attached to the bottom of the fire resistant center panel, or both the top panel and the bottom panel.

7. The core as recited in claim 6, 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.

8. The core as recited in claim 7, wherein the fire resistant center panel and the extruded fire resistant border are coated with an intumescent or fire resistant material.

9. The core as recited in claim 1, wherein the extruded fire resistant border comprises:

a first stile;

a second stile;

a first rail attached to the first stile and the second stile; and

a second rail attached to the first stile and the second stile.