Aerogel containing construction board
AssigneeJohns Manville
InventorsGuodong Zheng, Luke S Weith, Malay Nandi, Lance Wang, Jawed Asrar
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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.
Claims20
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;
- and
- wherein the binder is a crosslinking siloxane based emulsion.
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;
- the construction product has an R-value of at least 6.0 per inch;
- and
- the binder is a crosslinking siloxane based emulsion.
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;
- wherein the binder is a crosslinking siloxane based emulsion.
Dependencies are inferred from the claim text.