Aerogel containing foam board
AssigneeJohns Manville
InventorsGuodong Zheng, Luke S. Weith, Malay Nandi, Lance Wang, Jawed Asrar
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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.
Claims25
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, the mixture comprising:
- between 90 and 99 weight percent of the Aerogel;
- and
- between 1 and 10 weight percent of the carbon black;
- 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;
- the barrier material is entirely surrounded by the polyurethane foam;
- the construction product has an R-value of at least 8.0 per inch;
- and
- the 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.
An insulative construction product comprising:
- a polyurethane foam core;
- and
- a mixture of Aerogel and carbon black disposed within the polyurethane foam core, the mixture comprising:
- between 90 and 99 weight percent of the Aerogel;
- and
- between 1 and 10 weight percent of the carbon black;
- wherein:
- the polyurethane foam core includes between 10 and 90 percent by volume of the mixture;
- and
- the construction product has an R-value of at least 8.0 R/inch.
A method of forming a construction product with improved insulative properties, the method comprising:
- providing a foam core comprising polyurethane foam;
- positioning a mixture of Aerogel and carbon black within the foam core, the mixture comprising:
- between 90 and 99 weight percent of the Aerogel;
- and
- between 1 and 10 weight percent of the carbon black;
- wherein:
- the polyurethane foam core includes between 10 and 90 percent by volume of the mixture;
- the construction product has an R-value of at least 8.0 R/inch;
- and
- the construction product has a flame spread index of at most 30 or a smoke development index of at most 300 as measured according to ASTM E-84 test.
Dependencies are inferred from the claim text.