Gypsum composites used in fire resistant building components

1. A fire resistant composite product comprising:

a composite comprising gypsum in an amount sufficient to provide fire resistance wherein the amount is 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;

wherein the fibers comprise glass fibers, cellulose fibers, polyvinyl alcohol fibers and polypropylene fibers;

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

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, 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.

2. The fire resistant composite product 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).

3. The fire resistant composite product as recited in claim 1 , wherein the composite further comprises an aggregate in an amount of 10 to 25% by weight substantially homogeneously distributed through the composite.

4. The fire resistant composite product as recited in claim 1 , wherein the composite further comprises a starch in an amount of 2 to 7% by weight.

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

6. The fire resistant composite product 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.

7. The fire resistant composite product as recited in claim 1 , wherein the composite does not include any cement or flyash.

8. A fire resistant composite product comprising:

a composite consisting of 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, a rheology-modifying agent in an amount of 0.5 to 4% by weight, and optionally a vermiculite or clay in an amount of 0 to 10% by weight;

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

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, 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.

9. The fire resistant composite product as recited in claim 8 , wherein the fibers have a diameter of 6mm to 25mm.

10. The fire resistant composite product as recited in claim 8 , wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC).

11. The fire resistant composite product as recited in claim 8 , wherein the aggregate have an average particle diameter of 1 to 4mm.

12. The fire resistant composite product as recited in claim 9 , wherein the fire resistant component 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.

13. The fire resistant composite product as recited in claim 8 , wherein the composite does not include any cement or flyash.

14. A fire resistant composite product comprising:

a composite 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;

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

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, 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.

15. The fire resistant composite product as recited in claim 14 , wherein the fibers have a diameter of 6mm to 25mm.

16. The fire resistant composite product as recited in claim 14 , wherein the rheology-modifying agent comprises hydroxypropoyl methyl celluose (HPMC), methyl hydroxyethyl cellulose (MHEC), hydroxyethyl cellulose (HEC) or carboxymethyl cellulose (CMC).

17. The fire resistant composite product as recited in claim 14 , wherein the fire resistant component 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.

18. The fire resistant composite product as recited in claim 14 , wherein the composite does not include any cement or flyash.