# US 11,299,885 B2 · Aerogel containing foam board

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- Number: US 11,299,885 B2
- Document ID: US11299885B2
- Status: Granted
- Kind: B2
- Application number: 16/821,769
- Filed: 2020-03-17
- Published: 2020-07-09
- Granted: 2022-04-12
- Earliest claimed: 2017-12-01
- Assignees: Johns Manville
- Applicants: Johns Manville
- Inventors: Guodong Zheng; Luke S Weith; Malay Nandi; Lance Wang; Jawed Asrar
- Web page: https://patentgrep.com/patent/US11299885B2

## CPC

- E04B 2/7403: {with special measures for sound or thermal insulation including fire protection}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/20: foamed in situ
- B32B 27/065: {of foam}
- E04B 1/80: slab-shaped
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2266/0278: Polyurethane
- B32B 2266/126: Aerogel, i.e. a supercritically dried gel
- B32B 2305/022: Foam
- B32B 2307/304: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2605/08: Cars
- B32B 2605/12: Ships
- B32B 2605/16: Submarines
- E04B 1/803: {with vacuum spaces included in the slab}
- E04B 2001/742: {Use of special materials; Materials having special structures or shape}
- E04B 2103/00: Material constitution of slabs, sheets or the like
- E04C 2/205: {of foamed plastics, or of plastics and foamed plastics, optionally reinforced}
- Y02A 30/24: Structural elements or technologies for improving thermal insulation
- Y02B 80/10: Insulation, e.g. vacuum or aerogel insulation
- 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})
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS

## Abstract

An insulative construction product includes a polyurethane foam core and a mixture of Aerogel and carbon black that is disposed within the polyurethane foam core. The mixture of Aerogel and carbon black includes between 90 and 99 weight percent Aerogel and between 1 and 10 weight percent carbon black. The polyurethane foam core includes between 10 and 90 percent by volume of the of Aerogel and carbon black mixture and the construction product has an R-value of at least 8.0 R/inch.

## Claims

### Claim 1

A polyurethane foam based construction product having improved insulative properties, the construction product comprising:
a foam core comprising polyurethane foam; and
a mixture of Aerogel and carbon black disposed within the foam core; wherein:
the mixture of Aerogel and carbon black is enclosed within a barrier material such that the polyurethane foam does not directly contact the Aerogel and carbon black; and
the barrier material is entirely surrounded by the polyurethane foam so that the barrier material is fully enclosed within the foam core.

### Claim 2 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the Aerogel and carbon black are vacuum sealed within the barrier material.

### Claim 3 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the barrier material has a thickness of between 0.2 and 0.4 inches.

### Claim 4 (depends on 3)

The polyurethane foam based construction product of claim 3, wherein the construction product has a thickness of 1 inch.

### Claim 5 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the foam core includes a ratio of polyurethane foam to the mixture of Aerogel and carbon black of between 1.5 and 10.5.

### Claim 6 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the polyurethane foam based construction product includes between 10 and 90 percent by volume of the mixture of Aerogel and carbon black.

### Claim 7 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the barrier material forms a capsule or pouch and wherein the polyurethane foam based construction product includes a plurality of such capsules or pouches.

### Claim 8 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the polyurethane foam is polyisocyanurate foam.

### Claim 9 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein:
the polyurethane foam based construction product has an R-value of at least 8.0 per inch; and
the polyurethane foam based construction product has a flame spread index of at most 30 and a smoke development index of at most 300 as measured according to ASTM E-84 test.

### Claim 10 (depends on 1)

The polyurethane foam based construction product of claim 1, wherein the mixture of Aerogel and carbon black comprises:
between 90 and 99 weight percent Aerogel; and
between 1 and 10 weight percent carbon black.

### Claim 11

An insulative construction product comprising:
a foam core comprising a foam material; and
an Aerogel mixture disposed within the foam core; wherein:
the insulative construction product includes between 10 and 90 percent by volume of the Aerogel mixture;
the Aerogel mixture is contained within a barrier material that is entirely surrounded by the foam material so that the barrier material is fully enclosed within the foam core; and
the barrier material prevents direct contact between the foam material and the Aerogel mixture.

### Claim 12 (depends on 11)

The construction product of claim 11, wherein the Aerogel mixture comprises Aerogel and carbon black.

### Claim 13 (depends on 12)

The construction product of claim 12, wherein the Aerogel mixture comprises:
between 90 and 99 weight percent of the Aerogel; and
between 1 and 10 weight percent of the carbon black.

### Claim 14 (depends on 11)

The construction product of claim 11, wherein the barrier material is vacuum sealed.

### Claim 15 (depends on 14)

The construction product of claim 14, wherein the barrier material forms a capsule or pouch and wherein the construction product includes a plurality of capsules or pouches.

### Claim 16 (depends on 11)

The construction product of claim 11, wherein the foam material comprises polyurethane foam.

### Claim 17 (depends on 16)

The construction product of claim 16, wherein the polyurethane foam comprises polyisocyanurate foam.

### Claim 18 (depends on 11)

The construction product of claim 11, wherein construction product includes a ratio of foam material to Aerogel mixture of between 1.5 and 10.5.

### Claim 19

A method of forming a construction product with improved insulative properties, the method comprising:
providing a foam core comprising foam material;
positioning an Aerogel mixture within the foam core;
separating the Aerogel mixture from the foam material via a barrier material so that the foam material does not directly contact the Aerogel mixture and so that the barrier material is fully enclosed within the foam core;
wherein the foam core includes between 10 and 90 percent by volume of the Aerogel mixture.

### Claim 20 (depends on 19)

The method of claim 19, further comprising vacuum sealing the barrier material.

### Claim 21 (depends on 19)

The method of claim 19, wherein the barrier material forms a capsule or pouch and wherein the method further comprises positioning a plurality of capsules or pouches within the foam core.

### Claim 22 (depends on 19)

The method of claim 19, wherein positioning the Aerogel mixture within the foam core comprises:
pouring liquid foam around the Aerogel mixture so that the liquid foam entirely surrounds the Aerogel mixture; and
allowing the liquid foam to harden.

### Claim 23 (depends on 19)

The method of claim 19, wherein the foam material in the foam core is polyisocyanurate foam.

### Claim 24 (depends on 19)

The method of claim 19, wherein Aerogel mixture comprises:
between 90 and 99 weight percent Aerogel; and
between 1 and 10 weight percent carbon black.