Insulated building materials

Abstract

The present invention provides several methods and materials for use in building construction that may require air and water barrier, and water vapor permeability along with thermal or acoustic insulation. Several embodiments provide materials for a variety of building construction needs that can help build next generation green buildings.

1 . A material comprising an aerogel in a substantially planar form attached to a planar breathable material. 
     
     
         2 . The material of  claim 1 , wherein
 a) said breathable material is substantially impervious to air and optionally in building wrap form; or   b) said breathable material is a polymeric material substantially impervious to air and water, and said material is optionally in building wrap form; or   c) said breathable material further comprises a fibrous support material; or   d) said breathable material is present as two breathable layers substantially impervious to air and water; or   e) said breathable material is a cellulosic material.   
     
     
         3 . The material of  claim 1  further comprising a component to protect against ultraviolet radiation or ozone; or
 wherein the material has thermal insulation properties; or 
 wherein the material provides acoustic insulation; or 
 wherein the aerogel is hydrophilic; or 
 wherein the aerogel is hydrophobic; or 
 wherein the aerogel is water repellant; or 
 wherein the breathability is unidirectional; or 
 wherein the breathability is bidirectional; or 
 further comprising a structural component; or 
 wherein the breathable material is perforated; or 
 wherein the breathable material comprises a polyolefin, optionally in a microporous composite form; or 
 further comprising a resin; or 
 further comprising an adhesive; or 
 wherein the material is translucent; or 
 further comprising a polyurethane component; or 
 further comprising a fiber glass component; or 
 further comprising a fibrous component; or 
 further comprising a fibrous material, optionally in a mat, a felt or a batting form; or 
 further comprising at least a component selected from polystyrene, polyethylene, polypropylene, polybutylene, expanded polystyrene, polyester, acrylic, polycarbonate, fluoropolymers, fluorinated urethane, PTFE, expanded PTFE, phenol-formaldehyde, melamine-formaldehyde, a phenolic resin, carbon black, carbon, or copolymers thereof, wood, gypsum, or combinations thereof; or 
 wherein the aerogel and breathable material are laminated to each other with an adhesive; or 
 wherein the aerogel and breathable material are laminated with heat; or 
 wherein said material has a high water vapor transfer rate (WVTR); or 
 wherein said material has a water vapor transfer rate (WVTR) of at least 1 perm; or 
 wherein said material is in a building wrap form; or 
 wherein the breathable material has a thickness of about 0.25 mils to about 1000 mils; or 
 wherein the thermal insulation R value of said material is at least 2 per inch; or 
 further comprising a mold or mildew resistant agent. 
 
     
     
         4 . The material of  claim 2  further comprising a component to protect against ultraviolet radiation or ozone; or
 wherein the material has thermal insulation properties; or 
 wherein the material provides acoustic insulation; or 
 wherein the aerogel is hydrophilic; or 
 wherein the aerogel is hydrophobic; or 
 wherein the aerogel is water repellant; or 
 wherein the breathability is unidirectional; or 
 wherein the breathability is bidirectional; or 
 further comprising a structural component; or 
 wherein the breathable material is perforated; or 
 wherein the breathable material comprises a polyolefin, optionally in a microporous composite form; or 
 further comprising a resin; or 
 further comprising an adhesive; or 
 wherein the material is translucent; or 
 further comprising a polyurethane component; or 
 further comprising a fiber glass component; or 
 further comprising a fibrous component; or 
 further comprising a fibrous material, optionally in a mat, a felt or a batting form; or 
 further comprising at least a component selected from polystyrene, polyethylene, polypropylene, polybutylene, expanded polystyrene, polyester, acrylic, polycarbonate, fluoropolymers, fluorinated urethane, PTFE, expanded PTFE, phenol-formaldehyde, melamine-formaldehyde, a phenolic resin, carbon black, carbon, or copolymers thereof, wood, gypsum, or combinations thereof; or 
 wherein the aerogel and breathable material are laminated to each other with an adhesive; or 
 wherein the aerogel and breathable material are laminated with heat; or 
 wherein said material has a high water vapor transfer rate (WVTR); or 
 wherein said material has a water vapor transfer rate (WVTR) of at least 1 perm; or 
 wherein said material is in a building wrap form; or 
 wherein the breathable material has a thickness of about 0.25 mils to about 1000 mils; or 
 wherein the thermal insulation R value of said material is at least 2 per inch; or 
 further comprising a mold or mildew resistant agent. 
 
     
     
         5 . The material of  claim 3  further comprising a component to protect against ultraviolet radiation or ozone; or
 wherein the material has thermal insulation properties; or 
 wherein the material provides acoustic insulation; or 
 wherein the aerogel is hydrophilic; or 
 wherein the aerogel is hydrophobic; or 
 wherein the aerogel is water repellant; or 
 wherein the breathability is unidirectional; or 
 wherein the breathability is bidirectional; or 
 further comprising a structural component; or 
 wherein the breathable material is perforated; or 
 wherein the breathable material comprises a polyolefin, optionally in a microporous composite form; or 
 further comprising a resin; or 
 further comprising an adhesive; or 
 wherein the material is translucent; or 
 further comprising a polyurethane component; or 
 further comprising a fiber glass component; or 
 further comprising a fibrous component; or 
 further comprising a fibrous material, optionally in a mat, a felt or a batting form; or 
 further comprising at least a component selected from polystyrene, polyethylene, polypropylene, polybutylene, expanded polystyrene, polyester, acrylic, polycarbonate, fluoropolymers, fluorinated urethane, PTFE, expanded PTFE, phenol-formaldehyde, melamine-formaldehyde, a phenolic resin, carbon black, carbon, or copolymers thereof, wood, gypsum, or combinations thereof; or 
 wherein the aerogel and breathable material are laminated to each other with an adhesive; or 
 wherein the aerogel and breathable material are laminated with heat; or 
 wherein said material has a high water vapor transfer rate (WVTR); or 
 wherein said material has a water vapor transfer rate (WVTR) of at least 1 perm; or 
 wherein said material is in a building wrap form; or 
 wherein the breathable is breathable and has a thickness of about 0.25 mils to about 1000 mils; or 
 wherein the thermal insulation R value of said material is at least 2 per inch; or 
 further comprising a mold or mildew resistant agent. 
 
     
     
         6 . A building element comprising the material of  claim 1 . 
     
     
         7 . A building element comprising the material of  claim 2 . 
     
     
         8 . The building element of  claim 7  wherein said material is a roofing material or a flooring material; or wherein said element is a wall element. 
     
     
         9 . The building element of  claim 8  wherein said material is a roofing material or a flooring material; or wherein said element is a wall element. 
     
     
         10 . The building element of  claim 9  wherein said material is a roofing material or a flooring material; or wherein said element is a wall element. 
     
     
         11 . A building construction material comprising an aerogel in a planar form wherein the water vapor transfer rate of said construction material is at least about 5 perms. 
     
     
         12 . A method of manufacturing a material of  claim 1  comprising:
 a) providing a breathable material substantially impervious to air and water and permeable to water vapor; and combining the breathable material with at least an aerogel; or 
 b) providing at least a polymeric component substantially impervious to air and water and permeable to water vapor; and combining the breathable material with at least an aerogel; or 
 c) providing at least a fibrous support component; providing at least a breathable material substantially impervious to air and water and permeable to water vapor; and combining said fibrous component and breathable material with at least an aerogel component; or 
 d) providing at least a fibrous support component providing at least a breathable material substantially impervious to air and water and permeable to water vapor combining said fibrous component with at least an aerogel; and 
 laminating said combination with said breathable material; or 
 e) providing at least a cellulosic component; and combining said cellulosic component with at least an aerogel. 
 
     
     
         13 . A method of weatherizing a building comprising providing at least a material of  claim 1  in the envelope of the building. 
     
     
         14 . A method of weatherizing a building comprising providing at least a material of  claim 2  in the envelope of the building. 
     
     
         15 . The method of  claim 14   wherein said material further comprises a component to protect ultraviolet radiation or ozone; or   wherein said material has thermal insulation properties; or   wherein said material provides acoustic insulation; or   wherein the aerogel is hydrophilic; or   wherein the aerogel is hydrophobic; or   wherein the aerogel is water repellant; or   wherein the breathability is unidirectional; or   wherein the breathability is bidirectional; or   wherein said material further comprises a structural component; or   wherein the breathable material is perforated; or   wherein the breathable material comprises a polyolefin, optionally in a microporous composite form; or   wherein said material further comprises a resin; or   wherein said material further comprises an adhesive; or   wherein said material is translucent; or   wherein said material further comprises a polyurethane component; or   wherein said material further comprises a fiber glass component; or   wherein said material further comprises a fibrous component; or   wherein said material further comprises a fibrous component, optionally in a mat, a felt or a batting form; or   wherein said material further comprises at least a component selected from polystyrene, polyethylene, polypropylene, polybutylene, expanded polystyrene, polyester, acrylic, polycarbonate, fluoropolymers, fluorinated urethane, PTFE, expanded PTFE, phenol-formaldehyde, melamine-formaldehyde, a phenolic resin, carbon black, carbon, or copolymers thereof, wood, gypsum, or combinations thereof; or   wherein the aerogel and breathable material are laminated to each other with an adhesive; or   wherein the aerogel and breathable material are laminated with heat; or   wherein said material has a high water vapor transfer rate (WVTR); or   wherein said material has a water vapor transfer rate (WVTR) of at least 1 perm; or   wherein said material is in a building wrap form; or   wherein the breathable material is breathable and has a thickness of about 0.25 mils to about 1000 mils; or   wherein the thermal insulation R value of said material is at least 2 per inch; or   wherein said material further comprises a mold or mildew resistant agent.   
     
     
         16 . The material of  claim 1  wherein said breathable material is enveloping said aerogel component. 
     
     
         17 . The material of  claim 1  wherein said breathable material and said aerogel are in adjacent layers of said material. 
     
     
         18 . A material comprising a breathable material in a sheet or substantially planar form comprising essentially two surfaces wherein one surface is attached to an aerogel in a substantially planar form, wherein the material is in a form flexible enough for being rolled up. 
     
     
         19 . A material comprising a breathable material in a sheet or substantially planar form comprising essentially two surfaces wherein one surface is laminated to an aerogel in a substantially planar form. 
     
     
         20 . A material formed by attaching one surface of a breathable material in a sheet or substantially planar form comprising essentially two surfaces to an aerogel in a substantially planar form.