Aerogel containing construction board

Patent metadata

Field	Value
Publication number	US-2020048905-A1
Application number	US-201916659039-A
Country	US
Kind code	A1
Filing date	Oct 21, 2019
Priority date	Nov 6, 2017
Publication date	Feb 13, 2020
Grant date	—

Abstract

A construction product described herein includes a fiber core that includes a plurality of entangled glass fibers. The fiber core also includes a binder that bonds the plurality of entangled glass fibers together and an Aerogel material that is homogenously or uniformly disposed within the fiber core. In some instances, the fiber core includes between 40 and 80 weight percent of the Aerogel material. The construction product has an R-value of at least 6.5 per inch, a flame spread index of no greater than 5, and a smoke development index of no greater than 20 as measured according to the ASTM E-84 tunnel test.

First claim

What is claimed is:

1 . A glass fiber based construction product comprising:
a glass fiber core comprising:
a plurality of entangled coarse glass fibers having average fiber diameters of between 8 and 20 μm;
a plurality of entangled glass microfibers homogenously dispersed within the entangled coarse glass fibers, the glass microfibers having average fiber diameters of between 0.5 and 6 μm; and
a binder that bonds the plurality of coarse glass fibers and the plurality of glass microfibers together; and
a mixture of Aerogel and carbon black disposed within the glass fiber core; wherein the construction product has an R-value of at least 6.5 per inch and the construction product has a flame spread index no greater than 5 and a smoke development index no greater than 20 as measured according to ASTM E84.

2 . The glass fiber based construction product of claim 1 , wherein the glass fiber core includes between 1 and 15 weight percent of the coarse glass fibers and between 10 and 40 weight percent of the glass microfibers.

3 . The glass fiber based construction product of claim 1 , wherein the glass fiber core includes at least 50 weight percent of the Aerogel.

4 . The glass fiber based construction product of claim 1 , wherein the mixture of Aerogel and carbon black includes between 85 and 95 weight percent of the Aerogel and between 5 and 15 weight percent of the carbon black.

5 . The glass fiber based construction product of claim 4 , wherein the glass fiber core includes between 30 and 80 weight percent of the mixture of Aerogel and carbon black.

6 . The glass fiber based construction product of claim 1 , wherein the construction product has an R-value of at least 7.0 per inch.

7 . The glass fiber based construction product of claim 1 , wherein the glass fiber core includes between 5 and 20 weight percentage of the binder.

8 . The glass fiber based construction product of claim 1 , wherein the construction product is employed in one or more of the following application:
a residential structure; a commercial structure; an oil or gas refinery; a chemical plant; an automotive structure; and an aerospace structure.

9 . A construction product comprising:
a fiber core comprising a plurality of entangled glass fibers; a binder that bonds the plurality of entangled glass fibers together; and an Aerogel material disposed within the fiber core; wherein:
the fiber core includes between 30 and 90 weight percent of the Aerogel; and the construction product has an R-value of at least 6.0 per inch.

10 . The construction product of claim 9 , further comprising carbon black disposed within the fiber core.

11 . The construction product of claim 10 , wherein the glass fiber core includes between 30 and 90 weight percent of a mixture of the Aerogel and carbon black.

12 . The construction product of claim 9 , wherein the plurality of entangled glass fibers comprises: a plurality of entangled coarse glass fibers having average fiber diameters of between 8 and 20 μm; and
a plurality of entangled glass microfibers homogenously dispersed within the entangled coarse glass fibers, the glass microfibers having average fiber diameters of between 0.5 and 6 μm.

13 . The construction product of claim 12 , wherein the fiber core includes between 1 and 15 weight percent of the coarse glass fibers and between 10 and 40 weight percent of the glass microfibers.

14 . The construction product of claim 9 , wherein the fiber core includes at least 50 weight percent of the Aerogel.

15 . The construction product of claim 9 , wherein the construction product has an R-value of at least 6.5 per inch.

16 . The construction product of claim 9 , wherein the construction product has a flame spread index no greater than 5 and a smoke development index no greater than 20 as measured according to ASTM E-84 tunnel test.

17 . A method of forming a construction product comprising:
providing an aqueous solution that includes glass fibers and an Aerogel material dispersed within the glass fibers; pouring the aqueous solution onto a porous surface; removing water from the aqueous solution to form a wet laid mat or material mixture of the glass fibers and Aerogel material atop the porous surface; applying a binder to the wet laid mat or material mixture; and curing the binder to bond the glass fibers and Aerogel material together and thereby form a fiber core of the construction product.

18 . The method of claim 17 , wherein:
the fiber core includes between 30 and 90 weight percent of the Aerogel; the fiber core has an R-value of at least 6.5 per inch; and the fiber core has a flame spread index of no greater than 5 and a smoke development index of no greater than 20 as measured according to ASTM E-84 test.

19 . The method of claim 17 , wherein the aqueous solution also includes carbon black that is homogenously or uniformly dispersed within the glass fibers and the Aerogel material.

20 . The method of claim 19 , wherein the fiber core includes between 40 and 90 weight percent of the Aerogel material and carbon black.

Assignees

• Johns Manville

Inventors

• Zheng Guodong
• Weith Luke S
• Nandi Malay
• Wang Lance
• Asrar Jawed

Classifications

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title

• E04C2/16

  of fibres, chips, vegetable stems, or the like · CPC title

• C04B26/32

  containing silicon · CPC title

• C03C14/002

  the non-glass component being in the form of fibres, filaments, yarns, felts or woven material · CPC title

• C01B33/1585 Primary

  Dehydration into aerogels · CPC title