A method of applying a closed cell spray foam insulation may include spraying a first layer of a closed cell spray foam insulation into a wall cavity. A B-side mixture of the closed cell spray foam insulation may include a polyol blend having a polyester polyol having a functionality of at least about 3.0 and a polyether polyol. The method may include spraying at least one additional layer of the closed cell spray foam insulation against the first layer within 5 minutes of spraying the first layer.

An insulated panel assembly having improved insulative R-value. The insulated panel assembly comprises a cover panel, a first insulation layer, and at least one additional insulation layer, wherein the at least one additional insulation layer has a higher R-value than the first insulation layer. The first insulation layer is secured to the cover panel. The first insulation layer further forms at least one recessed portion. The at least one additional insulation layer is positioned in the at least one recessed portion of the first insulation layer. Examples of the at least one additional insulation layer may include vacuum insulated panels and modified atmosphere insulation panels.

Disclosed are polyurethane-based foams. The foams may have one or more vicrucidal/bactericidal agents. The foams may be used as filters that capture and/or inactivate viral particles, such as, virions associated with COVID-19. Also described are methods of making the foams and methods of using the foams.

Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

The present invention relates to a porous layer structure containing a base material and a polyurethane porous layer formed on the base material, wherein a moisture permeability A of the porous layer structure measured by JIS L1099 A-1 (calcium chloride method) is 2000 to 10000 g/(m.sup.2.Math.24h), a moisture permeability loss rate obtained by a predetermined formula from a moisture permeability B of the base material alone measured by JIS L1099 A-1 (calcium chloride method) and the moisture permeability A is 75% or less, and a peel strength at a bonding surface between the base material and the polyurethane porous layer is 0.7 kgf/inch or more.

A biodegradable, thermally insulated mailer and cooler, and method of making them, are disclosed. The thermally insulated packaging material are made from laminated starch foam and bio-plastic film. The lamination can be performed by heat bonding, without the use of an adhesive bonding agent, to produce biodegradable packaging materials that can pass ASTM and other certifications for home compostability and marine environment safety.

A method of applying a closed cell spray foam insulation may include spraying a first layer of a closed cell spray foam insulation into a wall cavity. A B-side mixture of the closed cell spray foam insulation may include a polyol blend having a polyester polyol having a functionality of at least about 3.0 and a polyether polyol. The method may include spraying at least one additional layer of the closed cell spray foam insulation against the first layer within 5 minutes of spraying the first layer.

Modified and connected foam wall structures and methods for making them are described. The wall structures include a frame, a foam panel attached to the frame, a foam layer disposed in a cavity defined by the frame, and a structural adhesive. The structural adhesive may be disposed in at least one of: (A) an aperture located within the foam layer, and (B) an aperture located between the foam layer and a frame member. In some cases, a cured structural adhesive is located between connecting members of adjacent foam wall structures.

An insulated panel assembly having improved insulative R-value. The insulated panel assembly comprises a cover panel, a first insulation layer, and at least one additional insulation layer, wherein the at least one additional insulation layer has a higher R-value than the first insulation layer. The first insulation layer is secured to the cover panel. The first insulation layer further forms at least one recessed portion. The at least one additional insulation layer is positioned in the at least one recessed portion of the first insulation layer. Examples of the at least one additional insulation layer may include vacuum insulated panels and modified atmosphere insulation panels.

A method of forming a building panel includes embossing dimples into a sheet, where the dimples extend outward from a plane, and expanding a foam core onto the plane and into portions of the dimples. The method may include forming dimples that are convex relative to the plane and the foam core or the sheet having a thin foil having a plastic protective coating. The method may include attaching a cellulosic layer to the foam core opposite the plane. Additionally, flow channels may be formed in the sheet between the dimples, such that expanding the foam core onto the plane substantially fills both the dimples and the flow channels. The method may include embossing concave dimples onto the plane and the foam core, such that expanding the foam core onto the plane substantially fills the concave dimples. The foam core and sheet may bond without adhesives.