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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Performance evaluation of a dynamic wall integrated with active insulation and thermal energy storage systems

Thermal energy storage systems in buildings can store cooling/heating energy during non-peak load hours or when renewable energy sources are available for later use when demanded. Using the building envelope as a thermal battery can help to shave the peak load, reduce the burden in electric grids, and enhance the occupant's thermal comfort. Sensible energy storage on wall systems such as thermally activated building systems can provide an active thermal storage strategy. However, most of the stored energy is used through passive means directed by the thermal lag, which can impede the on-demand release of the stored energy. Integrating active insulation systems with building thermal storage systems can increase the flexibility of charging and discharging time and duration. In this study, a wall system equipped with an active insulation system and thermally activated storage system was designed, and its performance on active cooling energy contribution was studied. The performances of energy storage (charging), release (discharging) of the thermal energy storage energy, and the active insulation system were studied separately and together as an integrated system. Results showed that the thermal properties of the thermal energy storage core material and the pipe spacing of both embedded pipes in the thermal energy storage and hydronic pipes used in the active insulation system affected the wall performance the most out of all the tested wall system parameters. During discharging, the heat flux into the wall was as high as 81.92 W/m 2 . This active insulation system's dynamic R-value varied between less than 1ft 2 •°F•h/BTU (0.18 m 2 •K/W) to 98% of the equally thick foam insulation's R-value.

25 ENERGY STORAGE↗
DOE OSTI2021

Energy performance analysis of smart wall system with switchable insulation and thermal storage capacity

The ever-increasing global energy demand and the issues caused by population growth and unsustainable energy resource usages have several environmental and economic impacts. The on-demand capability of dynamic wall systems with switchable insulation systems can contribute toward energy efficiency and reduced electric cost using "building-as-a-battery." In this paper, the performance of an exterior envelope system that employs a switchable insulation system is investigated. A COMSOL simulation was used to study the envelope performance under three switchable insulation locations in the wall system. The on and off switching cycle included insulating or conducting the exterior, interior, or both sides of the mass wall system. To validate the simulation work, an experimental test was conducted in climate chamber on a 4 × 8 in. wall system with identical wall components used in the COMSOL simulation. Results show a good agreement between the experiment and simulation results. The wall system with switchable insulation placed on the exterior side provided the highest interior inward heat flux when compared with the interior or split insulation. Also, an exterior switchable insulation system in addition to a thermal mass maintained a positive heat flow for more hours when the outdoor temperature was lower than the interior temperature.

Iffa, Emishaw↗
DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗
DOE OSTI2025

High Performance (R-10/inch) Clay-Cellulose-Silica Nanopore Insulation Board For New and Retrofit Buildings (Final Scientific Report)

The objective of Liatris’s 3-year DOE BENEFIT project was to develop and validate a high-performance, lightweight, aerogel-based insulation board of ≥R-10/inch at a cost of ≤$\$$1.50 per board foot using non-flammable inorganic nanocomposites. We have summarized each yearly goal below: Year 1 – Ambient dried inorganic/organic nanocomposite, R-6/inch Year 2 – Processing efficiency and cost down, R-8/inch at $\$$2.0/board-ft Year 3 – Scale up to continuous, pilot production of R-10 at ≤ $\$$1.50/board-ft Over the course of the project period, Liatris has successfully met or exceeded all of the goals outlined above. The project scope over 3 years was extensive, covering method development of ambient dried silica aerogels in Budget Period 1, process formulation and R-value improvement in Budget Period 2, and composite scale up with corporate partners in Budget Period 3. Over the course of the project Liatris has been able to progressively improve the thermal resistance properties from about R-6/in to > R-11/in, 2-3X the performance of conventional insulation products.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Comparative study on the overall energy performance between photovoltaic and Low-E insulated glass units

In this report a novel semi-transparent building integrated photovoltaic (BIPV) laminate was developed and introduced in this paper. It was produced by cutting standard mono-crystalline silicon solar cells into small strips and then making electrical connections between each strip before laminating the cells between two layers of glass. The overall energy performance and energy saving potential of the BIPV insulated glass unit (IGU) under real world conditions were identified through a side by side comparative study. Compared to the reference IGU, the BIPV IGU had lower solar heat gain coefficient (SHGC) but much higher U-factor. The average HVAC electricity saving of the BIPV IGU was about 10% relative to the reference IGU. Daylighting measurement and analysis were carried out to evaluate the trade-offs associated with the BIPV IGU between daylight, glare, and lighting energy use. The results indicated that the BIPV IGU is better than the reference IGU in reducing discomfort glare. However, if the most conservative viewpoint near the window is used for the assessment, a lower transmittance BIPV IGU is required to bring the overall discomfort levels below the perceptible level. Lastly, the net energy saving potential associated with the novel BIPV IGU was identified based on the power, thermal and daylighting performance. On average, the BIPV IGU saved 16.8% of the total electricity use of the room. Further studies and improvement on the energy conversion efficiency of solar cells, the optimal transmittance as well as the thermal properties would make this technology more energy-efficient and affordable.

14 SOLAR ENERGY↗
DOE OSTI2022

Hermetically sealed porous-wall hollow microspheres enabled by monolithic glass coatings: Potential for thermal insulation applications

Thermal insulation materials are crucial to improve the energy performance of buildings and industrial applications. We report an approach to create hermetically vacuum-sealed silica-based hollow microspheres that can lower the thermal conductivity of closed-cell insulation materials. The wall structure of these hollow microspheres includes a reticulated network of pores or channels that extend through the thickness of the wall. When a thin layer of glass material is applied to the wall exterior, followed by a vacuum-assisted thermal treatment process, the coated microsphere surfaces display a highly dense conformal coverage and near-complete elimination of surface porosity. The sealing efficiency of these microspheres is verified by trapping argon within their cavities as well as through evacuating their hollow cores. Notably, incorporating the evacuated microspheres into a polymer matrix resulted in ~27% enhancement in its thermal insulation performance and no notable loss of performance was observed following three months of exposure to ambient conditions. Thus, we believe that the present study offers a commercially viable strategy that opens the door to applications of such inorganic hollow particles in areas ranging from vacuum-based thermal insulation systems to catalysis, separation technologies, and medical fields.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using state of the art laser technology

The increasing complexity and scale of pulsed power systems necessitate effective maintenance strategies to ensure optimal performance and safety. This report investigates the automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using advanced laser cleaning technologies. The motivation for this research stems from the limitations of current manual cleaning methods, which are labor-intensive and pose health risks due to hazardous materials. The study addresses the problem of surface flashover, a significant issue affecting insulator performance, by evaluating two innovative cleaning techniques: Pulsed Laser Cleaning (PLC) and Flash Lamp Annealing (FLA). Experimental results demonstrate that PLC effectively restores the dielectric strength of Rexolite insulators, while FLA shows limited success. The findings highlight the potential for automated cleaning solutions to enhance safety and efficiency in insulator maintenance, paving the way for future advancements in pulsed power technology.

42 ENGINEERING↗
DOE OSTI2025

Foam-insulated cryo-compressed hydrogen storage vessels for buses

Here, large reductions (40 % vs. compressed gaseous hydrogen vessels and 17 % vs. vacuum insulated cryo-compressed vessels) in hydrogen storage system cost are possible by operating buses with foam-insulated cryo-compressed hydrogen (CcH 2 ) vessels. Detailed thermodynamic analysis reveals that large size and rapid H 2 consumption in buses compensate for the poor performance of foam insulation (∼100 times more conductive than vacuum multilayer insulation), resulting in compact and inexpensive H 2 storage systems with sufficient H 2 capacity for the longest routes (500 km) while maintaining previously identified advantages of CcH 2 systems: increased autonomy, rapid high density refueling, and improved safety, while simultaneously avoiding vacuum insulation stability problems resulting from composite resin outgassing.

Cryo-compressed↗
DOE OSTI2020

Mott localization in the van der Waals crystal CrI 3 : A GGA+DMFT study

Using the generalized gradient approximation plus dynamical mean-field theory (GGA+DMFT) we confirm the importance of multi-orbital dynamical correlations in determining the paramagnetic insulating state of CrI 3 . Furthermore, while the ferromagnetic phase reveals weak electronic correlation effects due to strong spin-orbital polarization, the Mott insulating state of paramagnetic CrI 3 crystal is shown to be driven by the interplay between orbital-dependent one-electron lineshape and multi-orbital electronic interactions. To probe the paramagnetic Mott insulating state we performed x-ray absorption spectroscopy (XAS) measurements for the two structural phases of CrI 3 . Our study is relevant to understanding the orbital-selective electronic structure reconstruction of Mott insulators and should be applicable to other van der Waals bonded materials from bulk to the ultrathin limit.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

A macromolecular assembly directed ceramic aerogel monolith material

Ceramic aerogels exhibit remarkable thermal insulation for energy efficient building applications, while it is indispensable to understand their nanoporous structure evolution to control their thermal regulation performance. In this study, we design and synthesize a lightweight porous silica aerogel monolithic material, and demonstrate its thermal insulation performance regulated by the morphology of porous nanostructures controlled by surfactant induced self-assembly. The micelle networks and in situ gas bubble formation guide the formation of uniform pores in the as-synthesized monolith, which shows superior thermal and acoustic insulation and robust mechanical stability with a thermal conductivity of 0.032 W m –1 K –1 , a soundproof performance improvement by 17% at a frequency of 800 Hz, and a 1.3 MPa compressive strength with a Young's modulus of 15 MPa. Lastly, these findings provide a new route to manufacture low-cost aerogel monolithic insulation materials for energy efficient building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

LCC-based framework for building envelope and structure co-design considering energy efficiency and natural hazard performance

Herein, this paper presents a life-cycle cost (LCC) informed co-design framework for building structures and envelope systems, holistically considering the influences of energy and natural hazard performance. The proposed method is consisted of a two-stage design and decision-making process, aiming to provide a quantitative guideline for building's structural and envelope co-design based on the its geographic locations. First, the building's structural configuration and envelope type are selected based on the life cycle cost. Then, the long-term cost effectiveness of various energy-saving building envelope options (e.g., high-performance glazing and insulation) is evaluated to refine the envelope design. The proposed co-design framework was demonstrated through the case study of a medium-size office building archetype in three locations with distinct climate conditions and seismic activities (i.e., Los Angeles, Memphis, and Boston). The results highlighted the interplay between building's structural (seismic) performance and the cost-effectiveness of energy-saving design options – e.g., for buildings located in high-seismic regions, seismic enhancing designs greatly reduce the paybak period of high performance building envelope by reducing the seismic loss; whereas for buildings located in regions with cold climate and low seismic risk such as Boston, spatial frame with high insulation building envelope shows the lowest LCC.

42 ENGINEERING↗
DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A non-volatile thermal switch for building energy savings

Compared with traditional static insulation, a thermally switchable building envelope could reduce annual heating and cooling loads by intermittently coupling to the outside environment when beneficial. Here, we demonstrate a voltage-actuated, contact/non-contact thermal switch that meets the unique challenges of this application. The switch is non-volatile, consuming electricity only briefly while switching and none to hold steady state. The switch ratio is 12, the off state has a low effective thermal conductivity of 0.045 W m -1 K -1 , comparable to fiberglass insulation, and the performance is stable over 1,000 switching cycles. Numerical simulations using real-world climate data show that combining this thermal switch with a thermal storage layer in a building envelope can yield annual energy savings of 9%-55% (heating) and 17%-76% (air conditioning), depending on the climate zone. The greatest benefits are realized when the exterior temperature crosses well above and below the desired interior temperature within a single 24 h period.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Thermal and Electrical Properties of Isocyanate Derived Organic Aerogels for Cryogenic Insulation Applications

The use and storage of cryogens such as liquefied nitrogen, helium, hydrogen among others requires reliable and efficient thermal insulation systems. Passive insulation from high performance materials that are well-known for their inherent low thermal conductivity would reduce the overall costs involved in design, manufacture and maintenance of such systems. One such class of materials are referred to as aerogels. These materials are known for their low density, high mesoporosity, high surface areas, low thermal conductivity and high acoustic impedance. Aerogels were invented by S.S. Kistler in 1931 and the most common type are those made of silica. However, the inherent fragility of silica aerogels makes them hard to mass produce, and therefore applications have been limited. A major breakthrough was introduced by our team almost 20 years ago with the invention of polymer crosslinked silica aerogels. Those materials shifted attention to all-polymer aerogels that have overcome all fragility issues associated with their inorganic counterparts. This study focuses on such polymeric aerogels that can be mass produced as large monoliths while maintaining the low thermal conductivity of traditional silica aerogels over a wide temperature range. Manufacturing flexibility of polymeric aerogels allows fabrication of blocks and sheets that can be applied in various configurations to insulate cryogenic and superconducting devices. The thermal conductivity with 80 K and room temperature boundary are reported as well as other properties (electrical), that need to be considered when designing devices for cryogenic applications.

Churu, Gitogo↗
DOE OSTI2022

Evaluation of Copper Catalytic Effects in Cable Insulation Polymers

This paper summarizes work performed to evaluate a phenomenon that occurs in electrical cable insulation polymers subjected to accelerated aging while in contact with copper metal. This effect, commonly known as the copper catalytic effect, is a result of chemical reactions that occur when copper ions diffuse into insulation polymers. This diffusion process is observed in various types of polymeric materials exposed to elevated temperatures and happens at the interface between the insulation and metallic components (e.g., conductor, shielding, etc.) in a cable. This polymer-metal interaction has only been observed in cables constructed with copper components (i.e., no interactions observed in cables with aluminum or other metal conductor/shielding) and results in a significant catalytic effect that increases the oxidation rate (e.g., aging) of the material. Under this research, the copper catalytic effects observed in cross-linked polyethylene, cross-linked polyolefin and ethylene propylene rubber insulated cables subjected to thermal accelerated aging were evaluated. These evaluations involved applying infrared spectroscopy, microscopy, and energy dispersive X-ray spectroscopy cross-sectional depth profiling to obtain an in-depth understanding of the aging characteristics of the materials under accelerated conditions. Based on the results of these assessments, the copper catalytic effect can have a significant impact on the mechanical, thermal, chemical, and electrical properties of cable insulation polymers. Here, the results acquired from this research provided the information needed to characterize the copper catalytic effects observed in these polymers, analyze how this phenomenon affected the polymer degradation process, and compare and understand the differences in the properties of the materials.

42 ENGINEERING↗