Moldable fire resistant composites

Abstract

Moldable fire resistant composites and processes for making moldable fire resistant composites are herein disclosed. According to one embodiment, a moldable fire resistant composite includes a first composite layer comprising an intumescent resin and a heat-dissipating component adhered to a second composite layer comprising a halogenated resin and a reinforcing structure.

What is claimed is: 
     
         1 . A fire resistant composite panel comprising:
 a first composite panel layer comprising a first intumescent resin and a heat-dissipating component; and   a second composite panel layer comprising a fire retardant material and at least one reinforcing material.   
     
     
         2 . The fire resistant composite panel of  claim 1 , wherein the first composite panel layer includes a finished surface, suitable for display on the exterior of a building. 
     
     
         3 . The fire resistant composite panel of  claim 2 , wherein the composite panel is formed using a mold, whereby the panel can be created in custom shapes. 
     
     
         4 . The fire resistant composite panel of  claim 1 , wherein the first composite panel layer is configured to impede flame spread and develop smoke when combusting of less than an index score of 450 as defined by the ASTM Designation E84-10. 
     
     
         5 . The fire resistant composite panel recited in  claim 1 , wherein the reinforcing structure is glass fiber. 
     
     
         6 . The fire resistant composite panel recited in  claim 1 , wherein the heat-dissipating component is sand. 
     
     
         7 . The fire resistant composite panel recited in  claim 1 , further comprising: a core layer incorporated with or adhered to the first composite layer to insulate or increase the stiffness of the first composite layer. 
     
     
         8 . The fire resistant composite panel recited in  claim 1 , wherein the heat-dissipating component forms part of an exposed surface of the first composite layer. 
     
     
         9 . The fire resistant composite panel recited in  claim 1  wherein second composite layer comprises alumina trihydrate. 
     
     
         10 . The fire resistant composite panel recited in  claim 1 , further comprising a core layer incorporated with or adhered to the second composite layer to insulate or increase the stiffness of the second composite layer. 
     
     
         11 . The fire resistant composite panel recited in  claim 1 , wherein the fire resistant composite panel is a building wind screen. 
     
     
         12 . A method of producing a fire resistant composite panel, the method comprising:
 adhering a first composite panel layer to a second composite panel layer, the first composite panel layer comprising a first intumescent resin and a heat-dissipating component, and the second composite layer comprising a fire retardant resin and a reinforcing structure.   
     
     
         13 . The method of  claim 12 , further comprising:
 creating a mold suitable to form a shape of an decorative panel of a building; and   placing the first composite panel layer against the mold, whereby the first composite panel layer takes the shape of the mold.   
     
     
         14 . The method of  claim 12 , further comprising:
 shaping the first composite panel layer into a desired shape of a decorative panel of a building.   
     
     
         15 . The method of  claim 14 , wherein the shaping is performed after the adhering. 
     
     
         16 . The method of  claim 12 , wherein the first composite panel layer includes a finished surface, suitable for display on the exterior of a building. 
     
     
         17 . The method of  claim 12 , wherein the first composite panel layer is configured to impede flame spread and develop smoke when combusting of less than an index score of 450 as defined by the ASTM Designation E84-10. 
     
     
         18 . The method of  claim 12 , further comprising:
 adhering a core layer to one of the first composite layer or the second composite layer.   
     
     
         19 . The method of  claim 12 , further comprising:
 installing the fire resistant composite panel onto an exterior surface of a building.   
     
     
         20 . The method of  claim 19 , wherein the fire resistant panel is a building wind screen.