# US 10,480,189 B2 · Aerogel containing construction board

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- Number: US 10,480,189 B2
- Document ID: US10480189B2
- Status: Granted
- Kind: B2
- Application number: 15/804,834
- Filed: 2017-11-06
- Published: 2019-05-09
- Granted: 2019-11-19
- Earliest claimed: 2017-11-06
- Assignees: Johns Manville
- Applicants: Johns Manville
- Inventors: Guodong Zheng; Luke S Weith; Malay Nandi; Lance Wang; Jawed Asrar
- Web page: https://patentgrep.com/patent/US10480189B2

## CPC

- E04C 2/296: composed of insulating material and non-metallic or unspecified sheet-material (E04C2/288 takes precedence)
- B32B 1/08: Tubular products
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 15/046: {of foam}
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/065: {of foam}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 29/007: {next to a foam layer}
- B32B 29/02: next to a fibrous or filamentary layer
- C01B 33/1585: {Dehydration into aerogels}
- C03C 13/00: Fibre or filament compositions (manufacture of fibres or filaments C03B37/00)
- C03C 14/002: {the non-glass component being in the form of fibres, filaments, yarns, felts or woven material}
- C04B 14/064: {Silica aerogel}
- C04B 20/0068: {Composite fibres, e.g. fibres with a core and sheath of different material}
- C04B 26/06: Acrylates
- C04B 26/32: containing silicon
- E04B 1/88: Insulating elements for both heat and sound
- E04B 1/90: slab-shaped
- E04C 2/16: of fibres, chips, vegetable stems, or the like
- E04C 2/20: of plastics
- E04C 2/22: reinforced {(E04C2/205 takes precedence)}
- E04C 2/30: characterised by the shape or structure (translucent E04C2/54)
- B32B 2255/12: on paper layer
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/025: Particulate layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/101: Glass fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2266/126: Aerogel, i.e. a supercritically dried gel
- B32B 2307/10: having particular acoustical properties
- B32B 2307/206: Insulating
- B32B 2307/304: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/308: Heat stability
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2307/72: Density
- B32B 2307/7265: Non-permeable
- B32B 2307/73: Hydrophobic
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2605/08: Cars
- B32B 2605/12: Ships
- B32B 2605/16: Submarines
- B32B 2605/18: Aircraft
- C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures
- C04B 2111/52: Sound-insulating materials
- C04B 2111/56: Compositions suited for fabrication of pipes, e.g. by centrifugal casting, or for coating concrete pipes
- C04B 2201/30: for heat transfer properties such as thermal insulation values, e.g. R-values
- E04B 2001/742: {Use of special materials; Materials having special structures or shape}
- E04B 2103/04: of plastics, fibrous material or wood
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## 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.

## Claims

### Claim 1

A glass fiber based construction product, the 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;
a binder that bonds the plurality of coarse glass fibers and the plurality of glass microfibers together, the glass fiber core including between 5 and 20 weight percentage of the binder;
a mixture of Aerogel and carbon black homogenously disposed within the glass fiber core, the mixture comprising:
between 85 and 95 weight percent of the Aerogel; and
between 5 and 15 weight percent of the carbon black;
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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

The glass fiber based construction product of claim 1, wherein the glass fiber core comprises between 0.5 and 2 weight percent of a hydrophobic agent.

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

The glass fiber based construction product of claim 1, wherein the glass fiber core includes between 50 and 80 weight percent of the mixture of Aerogel and carbon black.

### Claim 6 (depends on 1)

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

### Claim 7 (depends on 1)

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

### Claim 8 (depends on 1)

The glass fiber based construction product of claim 1, wherein the glass fiber core has a non-rectangular shape.

### Claim 9 (depends on 8)

The glass fiber based construction product of claim 8, wherein the glass fiber core is pipe or cylindrical shaped.

### Claim 10 (depends on 9)

The glass fiber based construction product of claim 9, wherein the pipe or cylindrical shaped glass fiber core includes a water impermeable facer coupled with an exterior surface.

### Claim 11 (depends on 9)

The glass fiber based construction product of claim 9, wherein the pipe or cylindrical shaped glass fiber core comprise an R-value of at least 7.0 per inch.

### Claim 12

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 homogenously or uniformly disposed within the fiber core;
wherein:
the fiber core includes between 40 and 80 weight percent of the Aerogel;
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 E-84 tunnel test.

### Claim 13 (depends on 12)

The construction product of claim 12, further comprising carbon black homogenously or uniformly disposed within the fiber core.

### Claim 14 (depends on 13)

The construction product of claim 13, wherein the glass fiber core includes between 30 and 90 weight percent of a mixture of the Aerogel and carbon black.

### Claim 15 (depends on 12)

The construction product of claim 12, 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.

### Claim 16 (depends on 15)

The construction product of claim 15, 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.

### Claim 17 (depends on 12)

The construction product of claim 12, wherein the fiber core includes at least 50 weight percent of the Aerogel.

### Claim 18 (depends on 12)

The construction product of claim 12, wherein the construction product has an R-value of at least 7.0 per inch.

### Claim 19 (depends on 12)

The construction product of claim 12, wherein the construction product has a non-rectangular shape.

### Claim 20 (depends on 19)

The construction product of claim 19, wherein the construction product is pipe or cylindrical shaped.

### Claim 21

A method of forming a construction product comprising:
providing an aqueous solution that includes glass fibers and an Aerogel material homogenously or uniformly 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;
wherein:
the fiber core includes between 40 and 80 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.

### Claim 22 (depends on 21)

The method of claim 21, further comprising applying pressure to the wet laid mat or material mixture during the curing process.

### Claim 23 (depends on 21)

The method of claim 21, wherein the aqueous solution also includes carbon black that is homogenously or uniformly dispersed within the glass fibers and the Aerogel material.

### Claim 24 (depends on 23)

The method of claim 23, wherein the fiber core includes between 40 and 90 weight percent of the Aerogel material and carbon black.

### Claim 25 (depends on 21)

The method of claim 21, wherein the glass fibers of the aqueous solution comprise:
coarse glass fibers having average fiber diameters of between 8 and 20 μm; and
glass microfibers homogenously dispersed within the coarse glass fibers, the glass microfibers having average fiber diameters of between 0.5 and 6 μm.

### Claim 26 (depends on 25)

The method of claim 25, 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.

### Claim 27 (depends on 21)

The method of claim 21, further comprising transferring the wet laid mat or material mixture to a mold and curing the binder within the mold such that the fiber core of the construction product has a non-rectangular shape.

### Claim 28 (depends on 27)

The method of claim 27, further comprising curing the wet laid mat or material mixture in the mold at a temperature of between 150 and 200 Celsius.

### Claim 29 (depends on 28)

The method of claim 28, wherein the wet laid mat or material mixture is cured in the mold for between 2 and 4 hours.

### Claim 30 (depends on 27)

The method of claim 27, wherein the mold is pipe or cylindrical shaped such that the fiber core of the construction product is pipe or cylindrical shaped.