Multilayered fire-resistant polymer composite and method for making same
AssigneeXeriant, Inc.
InventorsMartin Stloukal, Scott Duffy
Life of this patent
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Abstract
A versatile, multilayered composite construction material containing fiber-reinforced thermoplastic or thermosetting polymers treated with a non-toxic fire retardant and method of making same. Where used in the construction industry, the produced multilayered fire-resistant thermoplastic and fiber composite material can be formed or shaped into various construction products of different thicknesses and dimensions, such as, without limitation, interior wall panels, sheathing and structural boards.
Claims28
A method for producing a multilayered composite, comprising:
- a. providing a plurality of input materials for a base layer and at least one boundary layer;
- wherein the base layer comprises polymer and fiber particles having a first average particle size, and the boundary layer comprises polymer particles having a second average particle size smaller than the first average particle size;
- wherein a first boundary layer of the at least one boundary including a fire-retardant additive and the first boundary layer contains a higher concentration of the fire-retardant additive as compared to the base layer;
- b. using a first spreading machine to uniformly distribute the material for a first of the at least one boundary layer onto a conveyor surface;
- c. using a second spread machine to uniformly distribute the material for the base layer over the material for the first of the at least one boundary layer;
- and
- d. fusing or forming the first boundary layer and the base layer together using heat and pressure.
A method for producing a multilayered composite, comprising:
- a. forming a first solid boundary layer by spreading a plurality of boundary layer materials having a boundary layer fire-retardant concentration and fusing the plurality of boundary layer materials using heat and pressure;
- b. depositing a plurality of base layer materials having a base layer fire-retardant concentration, the base layer fire-retardant concentration being lower than the boundary layer fire-retardant concentration;
- c. applying heat and pressure to fuse the plurality of base layer materials to the first solid boundary layer to form the multilayered composite;
- and
- d. cooling the multilayered composite under compression to maintain a stratified structure.
A method for producing a multilayered composite, comprising:
- a. providing a plurality of input base layer materials for a base layer of the multilayered composite, the plurality of input materials having a first fire-retardant concentration;
- b. providing a plurality of boundary layer materials for a boundary layer of the multilayered composite, the plurality of boundary layer materials having a second fire-retardant concentration;
- c. depositing the plurality of boundary layer materials into a mold for creating an outer layer of the multilayered composite;
- d. depositing the plurality of base layer materials over the plurality of boundary layer material within the mold;
- and
- e. fusing the plurality of base layer materials and the plurality of boundary layer materials together using heat and/or pressure;
- wherein the second fire-retardant concentration is higher than the first fire-retardant concentration.
Dependencies are inferred from the claim text.