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

这一小型企业创新研究(SBIR)第一阶段项目将确定一种用于隔热应用的新型复合泡沫材料的可行性。国家建筑物(商业和住宅)绝缘泄漏造成的剩余能量损失导致电网效率低下和不稳定。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的添加剂，这是现有的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造成健康风险。不燃的ADC增加了泡沫的强度，而不会破坏使聚氨酯具有绝缘能力的封闭泡孔结构。因此，ADC的加入将把聚氨酯泡沫塑料的适用性扩展到结构应用，如屋顶衬垫、底板和侧壁。将展示的新型复合泡沫将是传统绝缘材料的安全和绿色替代，这将有助于提高我们建筑的能效，从而提高国家电网的能效。这个项目的更广泛的影响/商业潜力是多方面的和深远的。聚氨酯泡沫是现有的最好的绝缘材料之一；然而，其易燃性和燃烧副产品将其在绝缘材料市场的份额限制在3.4%(2.12亿美元)。在聚氨酯泡沫中加入从燃煤灰中回收的陶瓷是一种安全、绿色和成本效益高的机制，可以扩大聚氨酯泡沫的市场，并取代玻璃纤维等传统绝缘材料。灰渣陶瓷是不燃的，在泡沫中作为阻燃剂，使其变得安全，并极大地减少了材料对环境的负面影响。此外，在阿巴拉契亚地区，用于生产ADC的原材料--燃煤灰--供过于求。灰分衍生的陶瓷不仅将改善聚氨酯泡沫的性能，而且将它们纳入新的附加值产品将使该地区变得更加美丽，并在经济低迷的地区提供经济刺激。最终，将这种高效绝缘材料纳入新的和改造的建筑中，将减轻消费者的公用事业成本负担，并为国家的能源效率和安全做出贡献。

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.