Natural fiber composite building retrofit sips (structural insulated panels) and associated methods of manufacturing

Abstract

A NFCBRS system for installation on a surface of a building includes a body and one or more spacers. The body includes a core that includes a natural fiber wool that is bonded together and a composite skin that covers the core and includes a natural fiber impregnated with a thermoset resin. The one or more spacers are structured to be positioned between the body and a surface of a building to define a ventilation cavity between the body and the surface of the building. The ventilation cavity is structured to inhibit a build-up of moisture between the surface of the building and the body.

Description

NATURAL FIBER COMPOSITE BUILDING RETROFIT SIPS (STRUCTURAL INSULATED PANELS) AND ASSOCIATED METHODS OF MANUFACTURINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 529,890, filed July 31, 2023, and U.S. Provisional Patent Application No. 63 / 677,023, filed July 30, 2024, which are incorporated by reference as if disclosed herein in their entireties.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0002] This invention was made with U.S. Government support under Grant Number DE- EE0010920 awarded by the U.S. Department of Energy (DOE). The United States Government has certain rights in this invention.BACKGROUND

[0003] Residential buildings account for 60% of the total built surface area of the United States, with over two-thirds being single-family homes. Over half of these homes were constructed prior to 1980, when energy-efficiency standards were less strict. Although significant progress has been made in using renewable energy and improved building design to reduce building operational carbon (the emissions associated with the energy used to operate a building), little progress has been made in decreasing embodied carbon. Embodied carbon refers to the carbon emitted during the manufacturing of building materials and construction processes throughout a lifecycle of a building or an infrastructure. A recent UN Environmental Global Status Report estimated that by 2040, 57% of total CO2 emissions from the building industry will be attributed to embodied carbon.

[0004] The idea that high-efficiency building materials may be formed from a natural fiber textile may lead to ways to significantly reduce operational carbon. Moreover, such building materials would help address the high amounts of embodied carbon attributed to the building industry by utilizing a highly efficient, carbon-sequestering crop as its primary source of material.SUMMARY

[0005] Aspects of the present disclosure are directed to a natural fiber composite building retrofit structural insulated panel (NFCBRS) system for installing on a surface of a building. In some embodiments, the NFCBRS system includes a body comprising a core that includes a natural fiberwool that is bonded together and a composite skin structured to cover the core. In some embodiments the composite skin is comprised of a natural fiber impregnated with a thermoset resin. In some embodiments, the NFCBRS system includes one or more spacers structured to be positioned between the body and the surface of the building and to define a ventilation cavity between the body and the surface of the building. In some embodiments, the ventilation cavity is structured to inhibit a build-up of moisture between the surface of the building and the body.

[0006] In some embodiments, the NFCBRS system further includes a fastener configured to extend through the body and the one or more spacers in order to couple the body to the surface of the building. In some embodiments of the NFCBRS system, the one or more spacers comprise a first surface structured to contact the surface of the building and a second surface structured to contact the body. In some embodiments of the NFCBRS system, the first surface of the one or more spacers includes an adhesive layer configured to adhesively couple the first surface of the one or more spacer to the surface of the building. In some embodiments of the NFCBRS system, the one or more spacers are comprised of a resilient material. In some embodiments of the NFCBRS system, the one or more spacers are comprised of rubber.

[0007] In some embodiments of the NFCBRS system, the body comprises a U-shaped channel along at least one edge. In some embodiments of the NFCBRS system, the natural fiber wool of the core is bound together with a recycled binder, which in some embodiments is applied in about a 90: 10 weight ratio. In some embodiments of the NFCBRS system, the core comprises hemp. In some embodiments of the NFCBRS system, the body comprises a first overlap portion and a second overlap portion that are each configured to overlap a portion of an adjacent body. In some embodiments, the one or more spacers include at least one retainer structured to retain a portion of the body. In further embodiments of the NFCBRS system, the body defines at least one interlocking feature. In some embodiments of the NFCBRS system, the composite skin comprises an upper composite skin and a lower composite skin that are joined together. In some embodiments of the NFCBRS system, the composite skin includes a phenolic resin. In some embodiments of the NFCBRS system, the composite skin comprises hemp.

[0008] Aspects of the present disclosure are directed to methods of manufacturing a NFCBRS system. In some embodiments, the method includes structuring a body to comprise a core comprised of a natural fiber wool that is bonded together and a composite skin that is structured to cover the core and is comprised of a natural fiber impregnated with a thermoset resin. In some embodiments, the method comprises structuring at least one spacer to be positioned between the body and the surface of the building and to position the body a distance from the surface of thebuilding to define a ventilation cavity is defined between the body and the surface of the building. In some embodiments of the method, the ventilation cavity is structured to inhibit a build-up of moisture between the surface of the building and the body.

[0009] In some embodiments of the method, the structuring of the body further includes laying precut rectangular fiber preforms impregnated with a resin on a lower mold portion and lowering an upper mold portion onto the lower mold portion to consolidate a lower composite skin and cure the resin. In some embodiments of the method, the structuring of the body further includes separating the lower mold portion and the upper mold portion after the resin has cured and removing the lower composite skin and trimming away any flash. In some embodiments of the method, the structuring of the body further includes: placing the core on the lower composite skin; forming an upper composite skin in the same manner as the lower composite skin; placing the upper composite skin over a top of the core and sealing seams with lower composite skin with resin; clamping and heating the body until the resin is cured; and unclamping the body. In some embodies of the method, the structuring of the body is done using pultrusion. In some embodiments of the method, the natural fiber wool of the core is bound together with a recycled binder, which in some embodiments is applied in about a 90: 10 weight ratio.

[0010] Further embodiments of the method include structuring the at least one spacer to comprise a first end configured to contact the surface of the building and a second end configured to contact the body, and applying an adhesive layer to the first end to adhesively couple the first end of the at least one spacer to the surface of the building. Some embodiments of the method include forming the at least one spacer from a resilient material, such as rubber. Some embodiments of the method further include impregnating the composite skin with at least one flame retardant material. Some embodiments of the method further include structuring the composite skin from a natural fiber textile. Some embodiments of the method further include structuring the composite skin from an upper composite skin and a lower composite skin that are joined together. Some embodiments of the method further include structuring the composite skin from hemp.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The drawings show embodiments of the disclosed subject matter for the purpose of illustrating the invention. However, it should be understood that the present application is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

[0012] FIG. 1 schematically illustrates an embodiment of a NFCBRS system being applied to a building surface according to some embodiments of the present disclosure;

[0013] FIG. 2 schematically illustrates a close-up view of the embodiment of FIG. 1 at box B according to some embodiments of the present disclosure;

[0014] FIG. 3 schematically illustrates a cross sectional view of an embodiment of a body of the NFCBRS system according to some embodiments of the present disclosure;

[0015] FIG. 4 schematically illustrates and embodiment of a method of installing the NFCBRS system according to some embodiments of the present disclosure;

[0016] FIG. 5 illustrates a front perspective view of an embodiment of a bracket of another embodiment of the NFCBRS system according to some embodiments of the present disclosure;

[0017] FIG. 6 illustrates an oblique front view of an embodiment of the bracket of the NFCBRS system retaining a portion of a body according to some embodiments of the present disclosure;

[0018] FIG. 7 schematically illustrates a side view of an embodiment of the NFCBRS system showing a bracket retaining a body, an adjacent body and a filler piece positioned between the body and adjacent body according to some embodiments of the present disclosure; and

[0019] FIG. 8 schematically illustrates an embodiment of manufacturing the NFCBRS system according to some embodiments of the present disclosure.DETAILED DESCRIPTION

[0020] The following discussion relates to various embodiments of structural insulated panels (SIPS), a natural fiber composite building retrofit structural insulated panels (NFCBRS) system 100 and associated methods of manufacturing. It will be understood that the herein described versions are examples that embody certain inventive concepts as detailed herein. To that end, other variations and modifications will be readily apparent to those of sufficient skill. The terms “about” or “approximately” as may be used herein may refer to a range of 80%-125% of the claimed or disclosed value.

[0021] NFCBRS, such as those comprised of hemp, help to reduce the operational carbon of a significant portion of the building stock in the United States by making a cost-effective and easy- to-install building envelope or cladding retrofit system. Additionally, NFCBRS addresses the embodied carbon of such an effort by utilizing a highly efficient, carbon-sequestering crop, such as hemp, as its primary source of material. At a broader scale, NFCBRS, which rely on the local harvesting and processing of a natural fiber, such as hemp fiber, have the potential to create incentives for farmers to grow carbon-sequestering crops and for local communities to establishprocessing facilities for the extraction of fibers and herd from the raw plant. As the demand for NFCBRS and other products derived from a natural fiber textile continues to rise, so will the need for skilled labor in areas such as farming, processing, and manufacturing. This presents a unique opportunity for the establishment of local, biomaterial economies, allowing for underrepresented communities to gain access to well-paying jobs and build careers in multiple sectors of this industry

[0022] Described herein, and referring to FIGS. 1-3, are embodiments of an NFCBRS system 100 and examples of low-embodied carbon SIPs for use in said systems 100. In some embodiments, the NFCBRS system 100 may be a cladding system for an exterior building surface. In some embodiments, the NFCBRS system 100 may provide 15-25% HVAC energy savings when applied to residential buildings constructed with obsolete building codes. In some embodiments, the NFCBRS system 100 and / or the SIPs comprises an Rvalue that ofat least 4. In some embodiments, the NFCBRS system 100 and / or the SIPs comprises an R value that is greater than 3 / inch of material. In some embodiments, the NFCBRS system 100 and / or the SIPs comprises an R value that is at least 3.5 / inch of material. In some embodiments, the NFCBRS system 100 comprises a total thickness T (FIG. 2) that does not exceed PA”. In some embodiments, the NFCBRS system 100 significantly reduces an embodied carbon footprint when compared to other similar synthetic material products.

[0023] Still referring to FIGS. 1-3, the NFCBRS system 100 includes an SIP or body 110 and one or more spacers 130. In some embodiments, the body 110 includes a core 112 surrounded by a composite skin 114. In some embodiments, the core 112 is comprised of a natural fiber wool that is bonded together with a binder or bonding agent. In some embodiments, the natural fiber wool is formed into a dense mat. In some embodiments, the natural fiber wool and binder are heated for a period of time to cure the binder. In some embodiments, the binder is a recycled binder, such as polyethylene terephthalate (PET). In some embodiments, the natural fiber wool is bound with the binding agent in about a 90:10 weight ratio. In some embodiments, the weight ratio is about 85:15. In some embodiments the weight ratio is 80:20. In some embodiments, the weight ratio is about 95:5. In some embodiments, the core 112 is comprised of a natural fiber, such as, but not limited to, hemp, jute and flux. In some embodiments, the core 112 comprises at least one reinforcement fiber added to the natural fiber. In some embodiments, the at least one reinforcement fiber comprise polypropylene fiber. In some embodiments the natural fiber and the at least one reinforcement fiber are combined in about a 90:10-95:5 weight ratio, for example in a 92:8 weight ratio.

[0024] In some embodiments, the composite skin 114 (skin) is structured to be flexible and at least partially cover the core 112 of the body 110. In some embodiments, the skin 114 comprises a thickness of about 2.5 millimeters. In some embodiments, the skin 114 includes a natural fiber textile. In some embodiments, the skin 114 is comprised of a natural fiber such as, but not limited to, hemp, jute and flux. In some embodiments, the natural fiber of the skin 114 includes a textile that is woven or nonwoven. In some embodiments, the woven textile of the skin 114 includes , but is not limited to, twill, satin weave, or a plain weave. In some embodiments, the skin 114 is comprised of a nonwoven textile. In some embodiments, textile of the skin 114 comprises at least 3-ply. In some embodiments, the skin 114 is impregnate with a thermoset resin such as, but not limited to, a phenolic resin and a bioresin. In some embodiments, the skin 114 includes at least one bio-based ultra violet (UV) stabilizer and flame retardant in order to meet local building codes and to inhibit damage to the body 110 from UV radiation and fire. In some embodiments, the phenolic resin increases the durability, impact resistance and the fire resistance of the body 110. In some embodiments, the skin comprises a bioresin, which is a resin that derives some or all of its components from biological sources. In some embodiments, the skin 114 comprises an upper or top composite skin (top skin) 114a and a lower or bottom composite skin (bottom skin) 114b that are structured to surround the body 110. In some embodiments, the top skin 114a and the bottom skin 114b are bonded together at a seam using a resin to create the composite skin 114 that covers the core 112 of the body 110.

[0025] Some exemplary embodiments of the body 110 will now be discussed with continued reference to FIGS. 1-3, however the body 110 may comprise various sizes, shapes, profiles and / or configurations depending on the intended use. In some embodiments, the body 110 includes one or more overlap portions 116a, 116b that are structured to overlap a portion of an adjacent body 110’ when installed on a building surface 170. In some embodiments, the one or more overlap portions 116a, 116b inhibit moisture from penetrating an interface between adjacent bodies 110’. In some embodiments, the In some embodiments, the one or more overlap portions 116a 116b overlap a portion of an upper and / or lower surface of an adjacent body 110’. In some embodiments, the one or more overlap portions 116a, 116b cooperate with the one or more overlap portions 116a, 116b of adjacent bodies. In some embodiments, the one or more overlap portions may form tongue-and-groove connection between the body 110 and the adjacent body 110’. In some embodiments, the one or more overlap portions 116a, 116b may form a mortise and tenon joint. In some embodiments, the one or more overlap portions 116a, 116b may form another type of joint that is structured to join the body 110 and adjacent body 110’ together and inhibit moisture penetration through said joint. In some embodiments, the body 110 further includes one or moreinterlocking features 118 that are structured to engage complementary interlocking features 118 on an adjacent body 110 to further inhibit separation of the body 110 and the adjacent body 110’. In some embodiments, the interlocking features 118 are protrusions and complementary recesses. In some embodiments, the body 110 includes an architectural relief 127 formed on at least one edge of the body 110. In some embodiments, the architectural relief 127 may be formed as a result of an interaction between adjacent bodies 110. In some embodiments, an architectural relief may be formed on the body 110 between top and bottom edges of the body. In some embodiments, an architectural relief may be formed between right and left edges of the body 110.

[0026] In an embodiment, the one or more spacers 130 of the NFCBRS system 100 are formed as a single component with a first surface 132 structured to contact the building surface 170 and a second surface 134 structured to contact the body 110. In some embodiments, the first surface 132 includes an adhesive layer structured to adhesively couple the first surface 132 of the one or more spacers 130 to the building surface 170. In some embodiments, the one or more spacers 130 are comprised of a resilient material, such as rubber. In some embodiments, the one or more spacers are planar. In some embodiments, the first surface 132 and the second surface 134 of the one or more spacers 130 extend along parallel planes. In some embodiments, the first surface 132 and / or the second surface 134 may include one or more surface features, such as cross hatching, one or more bumps, ridges or the like in order to promote air circulation along the first and second surfaces 132, 134 of the one or more spacers 130.

[0027] A method 200 of installing an exemplary embodiment of a NFCBRS system 100 will now be explained with general reference to FIGS. 1-4. In some embodiments, the exemplary NFCBRS system 100 may be a cladding system for installation on a building surface 170 that is on an exterior of the building. Other embodiments of the NFCBRS system 100 are envisioned that may be installed on other exterior or interior building surfaces. In some embodiments, the building surface 170 is above the ground 50, however in other embodiments, the NFCBRS system 100 may be installed on a building surface 170 that is below the ground 50. In some embodiments, the building surface 170 may be at least partially covered with a vapor barrier.

[0028] At 202, one or more spacers 130 are coupled to the building surface 170. In an embodiment, the one or more spacers 130 are coupled to the building surface 170 in locations that oppose building supports, such as studs 150. At 204, a body 110 is positioned over at least one of the one or more spacers 130. At 206, the body 110 is fastened to the building surface 170 using one or more fasteners 140. In some embodiments, the one or more fasteners 140 include a fastening member 141 that extends through the body 110 and the one or more spacers 130. In anembodiment, at least one of the one or more fasteners 140 is positioned at the one or more overlap portions 116a, 116b of the body 110. In an embodiment, the fastening member 141 includes a threaded surface. In an embodiment, the one or more fasteners 140 are comprised of a weather resistant material such as plastic or metal or other suitable material. In an embodiment, the one or more spacers 130 are structured to space the body 110 away from the building surface 170 so as to define a ventilation space 136 between the body 110 (e.g., the bottom skin 114b of the body 110) and the building surface 170. In some embodiments, the ventilation space 136 may promote airflow between the body 110 and the surface of the building 170 to inhibit the degradation of the body and / or the surface of the building due to moisture build-up. In some embodiments, the ventilation space 136 improves the insulating capabilities of the NFCBRS system 100. In some embodiments, the ventilation space 136 may comprise a dimension of about 3-4 millimeters between the body 110 and the surface of the building 170. At 208, an adjacent body is positioned relative to the body 110 and fastened to the building surface 170 in a similar manner as previously described. In some embodiments, the adjacent body is identical to the body 110 and at least partially overlaps with the body 110 at corresponding overlap portions 116a, 116b. In some embodiments, the overlap portion of the adjacent body obscures the one or more fasteners 140 of the body 110 as is best shown in FIG. 2. In an embodiment, an adhesive, such as silicone, is applied to a portion of at least one of the overlap portions 116a, 116b of the body 110 prior to installation of the adj cent body in order to seal an interface between the bodies.

[0029] Turning to FIGS. 5 and 6, in some embodiments, the one or more fasteners 140 and the one or more spacers 130 are formed as a single component. In some embodiments, the one or more fasteners 140 include one or more brackets 142 that are structured to couple the body 110 to the building surface 170. In some embodiments, the one or more spacers 130 are positioned between the one or more brackets 142 and the building surface 170. In some embodiments, the one or more brackets 142 act as a spacer. In some embodiments, the one or more brackets 142 include a coupling portion 144 defining one or more openings 145 structured to at least partially accept a fastening member 141 to couple the one or more brackets 142 to the building surface 170. In some embodiments, the one or more brackets 142 include a retaining portion 146 including one or more retainers 148a, 148b that are structured to retain a portion of the body 110. In some embodiments, the one or more brackets 142 enable expansion and / or contraction of the body.

[0030] Referring to FIG. 7, after the one or more brackets 142 are attached to the building surface 170, a portion of the body 110 is inserted into the one or more retainers 148a. In the embodiment shown, a portion of an adjacent body 110’ in inserted or otherwise retained by a second retainer 148b. In some embodiments, the one or more brackets 142 create a separation or an architecturalrelief 127 between the body 110 and the adjacent body 110’. In some embodiments, a filler piece 120 is positioned between the bodies 110, 110’ (i.e., in the separation). In some embodiments, the filler piece 120 may form part of the architectural relief 127. In some embodiments, the filler piece 120 is formed in a similar manner as the body 110. In some embodiments, the filler piece 120 may include at least one exposed surface 122 that is exposed to an exterior of the system 100 or otherwise faces in a direction opposite of, or away from the ventilation space 136. In some embodiments, the at least one exposed surface 122 of the filler piece 120 may include one or more surface features that direct moisture away from, or along the exposed surface. In some embodiments, the at least one exposed surface 122 includes one or more aesthetic surface features.

[0031] In some embodiments, the body 110 (and adjacent body 110’) hangs on the one or more brackets and does not require direct coupling to the building surface 170 via one or more fastening members 141 as described in other embodiments. In some embodiments, retention of the filler piece 120 is done by the one or more brackets 142 and / or the body 110 and / or the adjacent body 110’. In some embodiments, the filler piece 120 is retained without direct a coupling to the building surface 120 or the one or more brackets 142. In some embodiments, the ventilation space 136 is created by the one or more brackets 142 being placed over the one or more spacers 130. In some embodiments, the one or more brackets 142 may act as a spacer to form the ventilation space 136 between the building surface 170 and the body 110 (and adjacent bodies 110’).

[0032] Referring to FIGS. 1 and 7, in some embodiments, the NFCBRS system 100 includes an adapter body / trim piece, or a starter / end body 125 at a bottom and / or top and / or a comer of a building surface 170. In some embodiments, the starter / end body 125 may be a different size from the body 110 and may include a top or bottom finished edge. In some embodiments, at least one edge of body 110 includes a finishing detail 128 or a cap or trim piece. In some embodiments, the finishing detail 128 is a U-shaped channel detail. In some embodiments, the finishing detail 128 comprises a planar surface. In some embodiments, the finishing detail 128 is formed as a separate component from the body 110 and is coupled to at least one edge of the body 110 to seal an end of the NFCBRS system 100, for example, at corners and / or edges of the building surface, such as at an expansion joint, a roof, a doorway, a window or a comer. In some embodiments, the finishing detail 128 is retained on the body 110 using one or more couplers that are coupled to the body or to the building structure 170. As shown in FIG. 1, an embodiment of the finishing detail 128 is installed around an edge of the body 110 that partially surrounds a window 172 positioned in the building surface 170. In some embodiments, the architectural relief 127 and / or the finishing detail 128 are structured to divert moisture along and / or away from the body 110.

[0033] Still referring to FIG. 7, in some embodiments, the finishing detail 128 may facilitate retention of the body 110 (and adjacent body 110’) by the one or more retainers 148a, 148b of the one or more brackets 142. In some embodiments, the finishing detail 128 may aid in retention of the filler piece 120. In some embodiments, multiple filler pieces 120 are used between the body 110 and adjacent body 110’. In some embodiments, the trim piece 125 may comprise a corner trim piece that is coupled to the building surface 170 and spaced apart from the body 110 or is at least partially overlapped by the body 110. In some embodiments, the one or more brackets 142 are used to space the body 110 apart from the trim piece 125. In some embodiments, the trim piece 125 is formed in a similar manner as the body 110.

[0034] An embodiment of a method 300 of manufacturing a body 110 will now be described with general reference to FIG. 8. At 302, the an upper and a lower composite skin 114a, 114b are formed. In an embodiment, the lower composite skin 114b is formed by laying precut rectangular fiber preforms impregnated with resin on a lower portion of a mold. In some embodiments, an upper mold portion is lowered onto the lower mold portion to consolidate the lower composite skin 114b and cure the resin of the lower composite skin 114b. In an embodiment, the lower mold portion and the upper mold portion are separated after the resin is cured and the lower composite skin 114b is removed from the lower mold and any flash is trimmed away. In an embodiment, the upper composite skin 114a is formed in the same manner as the lower composite skin 114b. At 304, the core 112 formed from natural fiber wool that is bonded together with a binding agent. At 306, the core 112 is covered by the upper and lower composite skins 114a, 114b. At 308, the seams between the upper composite skin 114a and the lower composite skin 114b are sealed with resin. At 310, the body 110 is clamped (or otherwise compressed) and heated for a period of time until the resin is cured. In some embodiments, the clamping and the heating act to bond the upper composite skin 114a and the lower composite skin 114b to the core 112. At 312, the finished body 110 is unclamped and cooled. In some embodiments, the body 110 may be formed using pultrusion, which is a continuous and a highly automated process that uses a heated die to give shape to the composite components.

[0035] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention.

Claims

CLAIMSWhat is claimed is:

1. A natural fiber composite building retrofit structural insulated panel (NFCBRS) system for installing on a surface of a building, comprising: a body comprising: a core comprised of a natural fiber wool that is bonded together; a composite skin structured to cover the core and comprised of a natural fiber impregnated with a thermoset resin; and one or more spacers structured to: be positioned between the body and the surface of the building; and define a ventilation cavity between the body and the surface of the building to inhibit a build-up of moisture between the surface of the building and the body.

2. The NFCBRS system of claim 1, wherein the one or more spacers comprise a resilient material.

3. The NFCBRS system of claim 1, wherein the one or more spacers are comprised of rubber.

4. The NFCBRS system of claim 1, wherein the a natural fiber wool that is bonded together with a recycled binder.

5. The NFCBRS system of claim 1, wherein the natural fiber wool of the core is bound together with a recycled binder in a 90: 10 weight ratio.

6. The NFCBRS system of claim 1, wherein the core comprises hemp.

7. The NFCBRS system of claim 1, wherein the one or more spacers include at least one retainer structured to retain a portion of the body.

8. The NFCBRS system of claim 1, wherein the composite skin comprises an upper composite skin and a lower composite skin that are joined together.

9. The NFCBRS system of claim 1, wherein the composite skin comprises a phenolic resin.

10. The NFCBRS system of claim 1, wherein the composite skin comprises a natural fiber textile.

11. The NFCBRS system of claim 1, wherein the composite skin comprises hemp.

12. A method of manufacturing a NFCBRS system for installation on a building surface, comprising: structuring a body to comprise: a core comprised of a natural fiber wool that is bonded together; a composite skin structured to cover the core and comprised of a natural fiber impregnated with a thermoset resin; and structuring at least one spacer to: be positioned between the body and the surface of the building; and position the body a distance from the surface of the building so that a ventilation cavity is defined between the body and the surface of the building to inhibit a build-up of moisture between the surface of the building and the body.

13. The method of claim 12, wherein the structuring of the body further comprises bonding the natural fiber wool of the core together with a recycled binder.

14. The method of claim 13, wherein the structuring of the body further comprises bonding the natural fiber wool of the core together with a recycled binder in a 90: 10 weight ratio.

15. The method of claim 12, further comprising structuring the at least one spacer to include at least one retainer structured to retain a portion of the body.

16. The method of claim 12, further comprising structuring the at least one spacer from rubber.

17. The method of claim 12, further comprising forming the composite skin from a natural fiber textile.

18. The method of claim 12, further comprising forming the composite skin from an upper composite skin and a lower composite skin that are joined together.

19. The method of claim 12, further comprising impregnating the composite skin with at least one flame retardant material.

20. The method of claim 12, further comprising structuring the composite skin from hemp.

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