# US 12,110,681 B2 · Fire resistant panel member and method for producing a fire resistant panel member > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,110,681 B2 - Document ID: US12110681B2 - Status: Granted - Kind: B2 - Application number: 17/661,396 - Filed: 2022-04-29 - Published: 2022-08-18 - Granted: 2024-10-08 - Earliest claimed: 2020-05-21 - Assignees: Talon Products LLC - Applicants: Talon Products LLC - Inventors: Donald Craig Ray, Sr. - Web page: https://patentgrep.com/patent/US12110681B2 ## CPC - B29D 99/0021: {provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix} - 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}) - B32B 27/08: of synthetic resin - B32B 27/20: using fillers, pigments, thixotroping agents - B32B 27/36: comprising polyesters - B29K 2105/0026: {Flame proofing or flame retarding agents} - B32B 2250/05: 5 or more layers - B32B 2250/24: All layers being polymeric - B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer - B32B 2255/26: Polymeric coating - B32B 2262/101: Glass fibres - B32B 2264/102: Oxide or hydroxide - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes - B32B 2307/54: Yield strength; Tensile strength - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2607/00: Walls, panels - E04B 1/942: {slab-shaped} - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A fire resistant panel member and a related method for producing a fire resistant panel member where the panel member includes a first layer, a second layer covering at least a portion of a surface of the first layer, the first and second layers each comprising a pigmented polyester resin and a first organic peroxide, a third layer covering at least a portion of a surface of the second layer, a substantially rigid core member covering at least a portion of a surface of the third layer, and a fourth layer covering at least a portion of a surface of the core member, the third and fourth layers each comprising a polyester resin, a flame retardant, a second organic peroxide, and a fiber material, wherein the panel member is configured to have an ASTM E84 Class I fire and smoke rating. ## Claims ### Claim 1 A fire and smoke resistant panel member, comprising: a first layer including a first pigmented polyester resin and a first organic peroxide, a second layer covering at least a portion of a surface of the first layer, the second layer including a second pigmented polyester resin and a second organic peroxide; a third layer covering at least a portion of a surface of the second layer, the third layer including a first polyester resin, a first flame retardant, a third organic peroxide, and a first fiber material; a substantially rigid core member covering at least a portion of a surface of the third layer; and a fourth layer covering at least a portion of a surface of the core member, the fourth layer including a second polyester resin, a second flame retardant, a fourth organic peroxide, and a second fiber material; wherein the panel member is configured to have an ASTM E84 Class I fire and smoke rating. ### Claim 2 (depends on 1) The panel member of claim 1, wherein the panel member has a flexural strength of within a range of about 34 Mpa to about 70 Mpa, and a flexural modulus of within a range of from about 1330 Mpa to about 3650 Mpa. ### Claim 3 (depends on 2) The panel member of claim 2, wherein the flexural strength is within the range of from about 51 Mpa to about 70 Mpa, and wherein the flexural modulus is within the range of from about 2723 to about 3650 Mpa. ### Claim 4 (depends on 1) The panel member of claim 1, wherein the panel member has a tensile strength of within a range of from about 58 Mpa to about 70 Mpa, and a tensile modulus of within a range of from about 5020 Mpa to about 6060 Mpa. ### Claim 5 (depends on 4) The panel member of claim 4, wherein the tensile strength is within the range of from about 62 Mpa to about 70 Mpa, and the tensile modulus is within the range of from about 5180 Mpa to about 6060 Mpa. ### Claim 6 (depends on 1) The panel member of claim 1, wherein the panel member has a flexural strength of within a range of about 60 Mpa to about 70 Mpa, a flexural modulus of within a range of from about 30000 Mpa to about 3650 Mpa, a tensile strength of within a range of from about 65 Mpa to about 70 Mpa, and a tensile modulus of within a range of from about 5500 Mpa to about 6060 Mpa. ### Claim 7 (depends on 1) The panel member of claim 1, wherein the first and/or the second fiber material comprises fiberglass. ### Claim 8 (depends on 1) The panel member of claim 1, wherein the core member comprises a thermoplastic material, a flame retardant material and a fiber reinforcement material. ### Claim 9 (depends on 1) The panel member of claim 1, wherein the second pigmented polyester resin is the same as the first pigmented polyester resin, the second and third organic peroxides are the same as the first organic peroxide, the second polymeric resin is the same as the first polymeric resin, and the second fiber material is the same as the first fiber material. ### Claim 10 (depends on 1) The panel member of claim 1, wherein the fire resistant panel is a laboratory wall panel. ### Claim 11 (depends on 1) The panel member of claim 1, wherein the first flame retardant and/or the second flame retardant comprises antimony and decabromodiphenyl ethane. ### Claim 12 A fire and smoke resistant panel member, comprising: a first layer and a second layer covering at least a portion of a surface of the first layer, the first and second layers each comprising a pigmented polyester resin and a first organic peroxide; a substantially rigid core member covering at least a portion of a surface of the second layer; and a third layer covering at least a portion of a surface of the second layer and a fourth layer covering at least a portion of a surface of the core member, the third and fourth layers each comprising a polyester resin, a flame retardant, a second organic peroxide, and a fiber material; and wherein the panel member is configured to have a maximum flame spread index of less than or equal to 25 and a smoke development index of less than or equal to 450. ### Claim 13 (depends on 12) The panel member of claim 12, wherein the panel member has a flexural strength of within a range of about 34 Mpa to about 70 Mpa, and a flexural modulus of within a range of from about 1330 Mpa to about 3650 Mpa. ### Claim 14 (depends on 13) The panel member of claim 13, wherein the flexural strength is within the range of from about 51 Mpa to about 70 Mpa, and wherein the flexural modulus is within the range of from about 2723 to about 3650 Mpa. ### Claim 15 (depends on 12) The panel member of claim 12, wherein the panel member has a tensile strength of within a range of from about 58 Mpa to about 70 Mpa, and a tensile modulus of within a range of from about 5020 Mpa to about 6060 Mpa. ### Claim 16 (depends on 15) The panel member of claim 15, wherein the tensile strength is within the range of from about 62 Mpa to about 70 Mpa, and the tensile modulus is within the range of from about 5180 Mpa to about 6060 Mpa. ### Claim 17 (depends on 12) The panel member of claim 12, wherein the panel member has a flexural strength of within a range of about 60 Mpa to about 70 Mpa, a flexural modulus of within a range of from about 30000 Mpa to about 3650 Mpa, a tensile strength of within a range of from about 65 Mpa to about 70 Mpa, and a tensile modulus of within a range of from about 5500 Mpa to about 6060 Mpa. ### Claim 18 (depends on 12) The panel member of claim 12, wherein the fiber material comprises fiberglass. ### Claim 19 (depends on 12) The panel member of claim 12, wherein the core member comprises a thermoplastic material, a flame retardant material and a fiber reinforcement material. ### Claim 20 (depends on 12) The panel member of claim 12, wherein the fire resistant panel is a laboratory wall panel. ### Claim 21 (depends on 12) The panel member of claim 12, wherein the flame retardant comprises antimony and decabromodiphenyl ethane. ### Claim 22 A fire and smoke resistant panel member, comprising: a first layer; a second layer covering at least a portion of a surface of the first layer, the first and second layers each comprising a polyester resin and a first organic peroxide, wherein the polyester resin of the first layer and/or the second layer is pigmented; a third layer covering at least a portion of a surface of the second layer; a substantially rigid core member covering at least a portion of a surface of the third layer; and a fourth layer covering at least a portion of a surface of the core member, the third and fourth layers each comprising a polyester resin, a flame retardant, a second organic peroxide, and a fiber material; wherein the panel member is configured to have an ASTM E84 Class I fire and smoke rating. ### Claim 23 (depends on 22) The panel member of claim 22, wherein the panel member is a laboratory wall panel.