SBIR Phase I: New Sustainable Expanded Urethane-Ceramic Composite Materials for Thermal Management Applications

这个小型企业创新研究（SBIR）第一阶段项目将确定一种新型复合泡沫材料用于隔热应用的可行性。 由于国家建筑物（商业和住宅）中的绝缘泄漏而导致的剩余能量损失导致电网的低效率和不稳定。这个问题可以用新的和改进的建筑材料来解决。在这个项目中，我们将使用从废弃的燃煤灰中回收的陶瓷作为聚氨酯泡沫塑料的添加剂，这是目前最高性能的绝缘材料之一。 灰衍生陶瓷（ADC）将取代卤化阻燃剂，后者在处理和燃烧过程中会带来健康风险。 不燃的ADC增加了泡沫的强度，而不会破坏赋予聚氨酯绝缘能力的闭孔结构。 因此，ADC的引入将使聚氨酯泡沫塑料的适用性扩展到结构应用中，例如屋顶垫层、底层地板和侧壁。 即将展示的新型复合泡沫将成为传统绝缘材料的安全、绿色替代品，这将有助于提高我们建筑物的能源效率，从而提高国家电网的能源效率。更广泛的影响/商业潜力该项目是多方面的，意义深远。聚氨酯泡沫是最好的绝缘材料之一;然而，其易燃性和燃烧副产品限制了其在绝缘材料市场的份额为3.4%（2.12亿美元）。 将从燃煤灰中回收的陶瓷转化为聚氨酯泡沫是一种安全、绿色且具有成本效益的机制，可用于扩大聚氨酯泡沫市场并取代玻璃纤维等传统绝缘材料。 灰衍生陶瓷是不可燃的，并在泡沫中作为阻燃剂，使其安全，大大减少了材料的负面环境影响。 此外，用于生产ADC的原材料，即燃煤灰，在阿巴拉契亚地区供过于求。 灰衍生陶瓷不仅将改善聚氨酯泡沫的性能，而且将其纳入新的增值产品将美化该地区，并为萧条地区提供经济刺激。 最终，将这种高效绝缘材料纳入新的和改造的建筑将减轻消费者的公用事业成本负担，并有助于国家的能源效率和安全。

This Small Business Innovation Research (SBIR) Phase I project will determine the feasibility of a new composite foam material for thermal insulation applications. Residual energy losses due to leaky insulation in the nation's buildings (commercial and residential) contribute to the inefficiency and instability in the electrical grid. This problem can be addressed with new and improved building materials. In this project, we will use ceramics recycled from discarded coal combustion ash as an additive in polyurethane foam, which is one of the highest-performance insulating materials available. The ash derived ceramics (ADCs) will replace halogenated flame retardants, which pose health risks during handling and combustion. The incombustible ADCs add strength to the foam without disrupting the closed cell structure that gives polyurethane its insulating capability. As a result, incorporation of ADCs will extend the applicability of polyurethane foam to structural applications, such as roof underlayment, subfloors, and sidewalls. The new composite foam to be demonstrated will be a safe and green alternative to traditional insulating materials, which will help improve the energy efficiency of our buildings and, thus, the nation's electric grid.The broader impact/commercial potential of this project is multi-faceted and far-reaching. Polyurethane foam is one of the best insulating materials available; yet, its flammability and combustion byproducts limit its share of the insulating materials market to 3.4% ($212 million). Incorporating ceramics recycled from coal combustion ash into the polyurethane foam is a safe, green, and cost-effective mechanism for growing the market for polyurethane foams and replacing traditional insulating materials like fiberglass. Ash derived ceramics are incombustible and serve as a flame retardant in the foam, making it safe and greatly reducing the negative environmental impacts of the material. Furthermore, the raw material used in the production of ADCs, coal combustion ash, is in oversupply in the Appalachian region. Not only will ash derived ceramics improve the performance of polyurethane foam, but their incorporation into new value-added products will beautify the region and provide economic stimulus in a depressed area. Ultimately, incorporating this high efficiency insulating material into new and retrofit construction will ease the utility cost burden on consumers and contribute to the nation's energy efficiency and security.