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A New Generation of Building Insulation by Foaming Polymer Blend Materials with CO2

ISTN extruded polystyrene (XPS) board produced in factory demonstration

ISTN extruded polystyrene (XPS) board produced in factory demonstration

Lead Performer: Industrial Science & Technology Network - Lancaster, PA
DOE Funding: $400,000
Cost Share: $80,000
Project Term: 1/1/2014 - 12/31/2015
Funding Opportunity Announcement: Building Technologies Innovations Program 2013 (DE-FOA-0000823)

Project Objective

This project aims to develop an environmentally clean, cost-effective building insulation with superior performance (R-9 to R-10 per inch) compared to existing insulation technologies available on the market. Instead of hydroflurocarbon,  it uses carbon dioxide as the blowing agent. This technology represents a highly valuable market opportunity given its ability to achieve maximum energy savings (at equal or lower cost) across a variety of thermal insulating applications, such as building foundations and walls, and refrigeration and heating, ventilation, and air conditioning applications.

The specific aims of this project are:

  1. Developing advanced material composites with pore morphology control and CO2 foaming to achieve R-6 per inch foam building insulation at competitive costs;
  2. Incorporating nanotechnology structures and materials that will significantly improve upon R-6 by reaching foam insulation values of R-9 to R-10 per inch at the pilot scale in two years (at competitive manufacturing costs), and subsequently commercializing this new product in the building materials market with an industrial and/or venture-capital partner from years 3 to 5.

Project Impact

The Industrial Science & Technology Network (ISTN)  estimates that the commercialization of this technology would reduce U.S. energy consumption related to building envelope components by 7%, which equates to an annual U.S. energy savings of 0.361 quads, or $8 billion in annual economic savings.

Contacts

DOE Technology Manager: Karma Sawyer
Performer: Arthur Yang, Industrial Science & Technology Network

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