Insulation for modular buildings

Patent metadata

Field	Value
Publication number	US-2018339491-A1
Application number	US-201815988256-A
Country	US
Kind code	A1
Filing date	May 24, 2018
Priority date	May 24, 2017
Publication date	Nov 29, 2018
Grant date	—

Abstract

An article including one or more foam material layers and one or more nonwoven fibrous layers. The article is adapted to be used as insulation within a wall or hollow cavity. The article is a material that is acoustically and thermally functional, thermally insulative, easy to handle and fabricate, easy to slide into wall channels or place into wall, light weight, non-shedding, non-toxic, no mold/mildew, continuous (longer lengths in one piece), resistant to tearing/breaking, that has a high R-value, or a combination thereof.

First claim

What is claimed is:

1 . An article comprising:
a. one or more foam material layers; b. one or more nonwoven fibrous layers;
wherein the article is adapted to be used as insulation within a wall or hollow cavity.

2 . The article of claim 1 , wherein the one or more foam material layers is sandwiched between two nonwoven fibrous layers.

3 . The article of claim 1 , wherein the one or more nonwoven fibrous layers are sandwiched between two foam material layers.

4 . The article of claim 1 , wherein the article exhibits an R-value of about 12° F.·ft 2 ·h/Btu or greater at a thickness of about 60 mm to about 70 mm.

5 . The article of claim 1 , wherein the one or more nonwoven fibrous layers are adapted to provide protection to the one or more foam material layers.

6 . The article of claim 1 , wherein the one or more nonwoven fibrous layers are compressible to fit within the wall or hollow cavity.

7 . The article of claim 1 , wherein the article is mold or mildew resistant.

8 . The article of claim 1 , wherein the article is non-shedding.

9 . The article of claim 1 , wherein the article is non-toxic.

10 . The article of claim 1 , wherein the article or one or more layers thereof is thermoformable to allow the article to be shaped to fit in an area to be insulated.

11 . The article of claim 1 , wherein the foam material layer is formed of a polyisocyanurate (PIR) board.

12 . The article of claim 1 , wherein the foam material layer is formed via a foam-in-place process after being applied to one or more of the fibrous layers.

13 . The article of claim 1 , wherein the nonwoven fibrous layer includes fibers selected from polyester (PET), polyacrylonitrile (PAN), oxidized polyacrylonitrile (Ox-PAN, OPAN, or PANOX), aramid, olefin, polyamide, imide, polyetherketone (PEK), polyetheretherketone (PEEK), Poly(ethylene succinate), polyether sulfonate (PES), mineral, ceramic, natural or another polymeric fiber.

14 . The article of claim 1 , wherein the fibrous layer includes bicomponent fibers.

15 . The article of claim 1 , wherein the fibrous layer is formed by distributing fibers via an air laying process.

16 . The article of claim 1 , wherein the fibrous layer is formed by distributing fibers via a carding and lapping process.

17 . The article of claim 1 , wherein the fibrous layer includes one or more additives selected from recycled waste, virgin (non-recycled) materials, binders, fillers (e.g., mineral fillers), adhesives, powders, thermoset resins, coloring agents, flame retardants, and longer staple fibers.

18 . The article of claim 1 , wherein the article includes one or more fasteners for securing the article within an area to be insulated, or for holding the article in a desired shape.

19 . The article of claim 1 , wherein the article includes one or more adhesives for securing the article within an area to be insulated, or for holding the article in a desired shape.

20 . The article of claim 1 , wherein the article is flame and smoke retardant, to comply to architectural and building codes.

Assignees

• Zephyros Inc

Inventors

• Hursit Eren
• Bush Kendall

Classifications

• B32B2419/00

  Buildings or parts thereof · CPC title

• B32B2262/0253

  Polyolefin fibres · CPC title

• B32B27/08

  of synthetic resin · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title

• B32B15/043

  of metal (B32B15/01 takes precedence) · CPC title