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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Design and Fabrication of Polyisocyanurate Foams toward Significantly Enhanced Thermal Resistivity

Developing high-performance thermal insulation is vital for addressing the ongoing global demand for reduced energy costs. Polyisocyanurate (PIR) foams are commonly used in residential and commercial buildings and in various industrial applications owing to their relatively high thermal insulation properties and fire resistivity. Here, this study aims to further improve the thermal resistivity of PIR foams by (1) incorporating low thermal conductivity blowing agents; (2) tailoring the anisotropy of their cells; (3) tuning polymeric isocyanate quantities; and (4) incorporating a facer barrier, while using steps that easily integrate into current manufacturing processes for PIR foams. The resulting PIR foams exhibit a significant enhancement in thermal resistivity, achieving initial values as high as 8.3 h·ft 2 ·°F/Btu/in., commonly abbreviated as R-8.3/in., which is a 20% improvement compared with that of commercially used PIR foams that achieve approximately R-7/in. The detailed analysis of thermal conductivity measurements, mechanical testing, and morphological characterization elucidates the structure–property relationships. The developed high-performance PIR foams provide a critical pillar for next-generation high-performance insulation, offering promising thermal insulation for buildings and many other applications that have a significant effect on global energy costs.

Anisotropic pores↗
NASA NTRS1988

Development of polyisocyanurate pour foam formulation for space shuttle external tank thermal protection system

Four commercially available polyisocyanurate polyurethane spray-foam insulation formulations are used to coat the external tank of the space shuttle. There are several problems associated with these formulations. For example, some do not perform well as pourable closeout/repair systems. Some do not perform well at cryogenic temperatures (poor adhesion to aluminum at liquid nitrogen temperatures). Their thermal stability at elevated temperatures is not adequate. A major defect in all the systems is the lack of detailed chemical information. The formulations are simply supplied to NASA and Martin Marietta, the primary contractor, as components; Part A (isocyanate) and Part B (poly(s) and additives). Because of the lack of chemical information the performance behavior data for the current system, NASA sought the development of a non-proprietary room temperature curable foam insulation. Requirements for the developed system were that it should exhibit equal or better thermal stability both at elevated and cryogenic temperatures with better adhesion to aluminum as compared to the current system. Several formulations were developed that met these requirements, i.e., thermal stability, good pourability, and good bonding to aluminum.

Harvey, James A.↗
NASA NTRS1972

Fire retardant polyisocyanurate foam

Fire retardant properties of low density polymer foam are increased. Foam has pendant nitrile groups which form thermally-stable heterocyclic structures at temperature below degradation temperature of urethane linkages.

Riccitiello, S. R.↗
DOE OSTI2025

Enhancing The Thermal Resistivity of Rigid Polyisocyanurate Foam Insulation

The development of rigid polyurethane foam insulation has garnered considerable attention because of its promising applications in the buildings and construction industry. Its low thermal conductivity makes it an attractive choice for improving energy performance in buildings. Current Rigid Polyurethane foams have thermal resistivity (R-value/in.) 5.5 to 6.5 h.ft2F/BTU/in.· that could be further improved by diminishing the heat transfer through the foam matrix. Nevertheless, minimizing both conduction (through gas and solid) and radiation simultaneously in porous solids is a significant challenge due to the trade-off between these two mechanisms. This study focuses on improving the R-value of the insulation foams via several strategies: such as type and the amount of the surfactants, blowing agent content and precooling and premixing polyol mixture. These methods optimized thermal properties of the PIR foams, achieving R/in. as high as 8.3. This excellent R/in. is anticipated to be a critical factor in significantly advancing the thermal insulation performance of rigid polyurethane cellular foams, thereby enhancing their efficacy in energy-efficient building applications.

Wanasinghe Mudiyanselage Pahala Gedara, Shiwanka V↗
NASA NTRS1995

Foam, Foam-resin composite and method of making a foam-resin composite

This invention relates to a foam, a foam-resin composite and a method of making foam-resin composites. The foam set forth in this invention comprises a urethane modified polyisocyanurate derived from an aromatic amino polyol and a polyether polyol. In addition to the polyisocyanurate foam, the composite of this invention further contains a resin layer, wherein the resin may be epoxy, bismaleimide, or phenolic resin. Such resins generally require cure or post-cure temperatures of at least 350.degree. F.

Cranston, John A.↗
NASA NTRS2012

Polyurea-Based Aerogel Monoliths and Composites

aerogel insulation material was developed that will provide superior thermal insulation and inherent radiation protection for government and commercial applications. The rubbery polyureabased aerogel exhibits little dustiness, good flexibility and toughness, and durability typical of the parent polyurea polymer, yet with the low density and superior insulation properties associated with aerogels. The thermal conductivity values of polyurea-based aerogels at lower temperature under vacuum pressures are very low and better than that of silica aerogels. Flexible, rubbery polyurea-based aerogels are able to overcome the weak and brittle nature of conventional inorganic and organic aerogels, including polyisocyanurate aerogels, which are generally prepared with the one similar component to polyurethane rubber aerogels. Additionally, with higher content of hydrogen in their structures, the polyurea rubber-based aerogels will also provide inherently better radiation protection than those of inorganic and carbon aerogels. The aerogel materials also demonstrate good hydrophobicity due to their hydrocarbon molecular structure. There are several strategies to overcoming the drawbacks associated with the weakness and brittleness of silica aerogels. Development of the flexible fiber-reinforced silica aerogel composite blanket has proven to be one promising approach, providing a conveniently fielded form factor that is relatively robust in industrial environments compared to silica aerogel monoliths. However, the flexible, silica aerogel composites still have a brittle, dusty character that may be undesirable, or even intolerable, in certain application environments. Although the cross - linked organic aerogels, such as resorcinol- formaldehyde (RF), polyisocyanurate, and cellulose aerogels, show very high impact strength, they are also very brittle with little elongation (i.e., less rubbery). Also, silica and carbon aerogels are less efficient radiation shielding materials due to their lower content of hydrogen element. The invention involves mixing at least one isocyanate resin in solvent along with a specific amount of at least one polyamine hardener. The hardener is selected from a group of polyoxyalkyleneamines, amine-based polyols, or a mixture thereof. Mixing is performed in the presence of a catalyst and reinforcing inorganic and/or organic materials, and the system is then subjected to gelation, aging, and supercritical drying. The aerogels will offer exceptional flexibility, excellent thermal and physical properties, and good hydrophobicity. The rubbery polyurea-based aerogels are very flexible with no dust and hydrophobic organics that demonstrated the following ranges of typical properties: densities of 0.08 to 0.293 g/cu cm, shrinkage factor (raerogel/rtarget) = 1.6 to 2.84, and thermal conductivity values of 15.2 to 20.3 mW/m K.

Lee, Je Kyun↗
DOE OSTI2026

Minimized aging of isocyanurate-based rigid cellular foams for buildings through tailored barrier facers and optimized formulation

The thermal resistivity (h·ft 2 ·°F/Btu/in.) of closed-cell rigid foam insulation materials significantly decreases over time. Diffusion-tight facers are designed to significantly enhance initial thermal resistivity and long-term thermal performance by preventing gas diffusion into the foam cells and inhibiting the escape of low thermal conductivity blowing agents. In addition to the gas diffusion property of the facer film, adhesion between the foam and the facer is crucial for achieving diffusion-tight bonding. Here, this study addresses the challenge of thermal aging by investigating how facer film properties and foam formulation influence the durability of thermal performance. A systematic evaluation was conducted to understand the effects of polymeric barrier films, surface treatments, facer coverage, and foam matrix rigidity on thermal resistivity over time. Key findings reveal that diffusion-tight facers, particularly those with metallized layers and compatible heat seal layers, significantly reduce gas exchange and improve foam-facer adhesion. The optimized system, incorporating barrier facers and a tailored polyisocyanurate foam formulation, achieved initial and aged thermal resistivity values after 200 days of approximately 8.3 and 7.4 h ft 2 ·°F/Btu/in., respectively representing only a 10 % reduction compared to a 17 % reduction observed in control samples without facers. Notably, polyurethane spray foams with facers exhibited only a 4 % reduction in thermal resistivity, compared to a 23 % decrease in control samples, demonstrating nearly six times better retention of thermal performance. This innovative facer technology presents a promising solution for reducing energy costs and represents a significant advancement in optimizing energy management for building envelopes in future technologies. This technology can also be adapted for other applications that necessitate the preservation of long-term thermal performance.

Wanasinghe, Shiwanka Vidarshi [Oak Ridge National ↗
NASA NTRS1972

Synthesis of temperature and solvent-resistant polymers

Development of silicone polymers, polyimides, and polyisocyanurates for use as insulation, coatings, or adhesives under adverse environmental conditions is discussed. Chemical structure of the organic compounds is presented. Physical and mechanical properties of the compounds are analyzed.

Webster, J. A.↗
NASA NTRS1971

Materials for foam type insulation

An internal foam fabrication is one of the concepts being considered for cryogenic insulation on the hydrogen tanks of the shuttle vehicle. The three-dimensional polyurethane used on the S-4 B tanks failed to meet the higher temperature requirements of the shuttle vehicle, however, and other foams under consideration include polyisocyanurates, polyphenylene oxides, polyimides, and polybenzimidazoles. Improved adhesive systems for attaching the foams to the interior tank wall are under study.

Hill, W. E.↗
NASA NTRS1971

Heat shields for aircraft - A new concept to save lives in crash fires.

A passenger compartment surrounded by a fire-retardant shell, to protect the occupants long enough for the fire to burn out or for fire-fighting equipment to reach the aircraft and extinguish it, is proposed as a new concept for saving lives in crash fires. This concept is made possible by the recent development of two new fire-retardant materials: a very lightweight foam plastic, called polyisocyanurate foam, and an intumescent paint. Exposed to heat, the intumescent paint expands to many times its original thickness and insulates the surface underneath it. Demonstration tests are illustrated, described and discussed. However, some problems, such as preventing fuselage rupture and protecting windows, must be solved before such a system can be used.

Neel, C. B.↗
NASA NTRS1972

Analysis of volatile combustion products and a study of their toxicological effects.

An experimental program was conducted to study the thermochemical, flammability and toxicological characteristics of uncoated and coated polyisocyanurate foams. The coatings used were fluorinated copolymer and an intumescent material. Combustion and pyrolysis gases were analyzed by gas chromatography and mass spectrometry. The LD-50 and LD-100 tests were performed on Sprague-Dawley rats housed in an environmental chamber. The isocyanurate foam, fluorinated-copolymer-coated foam, and the intumescent-coated foam were found to have excellent flammability and insulation characteristics, although smoke development was substantial.

Seader, J. D.↗
NASA NTRS1975

Ablative overlays for Space Shuttle leading edge ascent heat protection

Ablative overlays were evaluated via a plasma-arc simulation of the ascent pulse on the leading edge of the Space Shuttle Orbiter. Overlay concepts included corkboard, polyisocyanurate foam, low-density Teflon, epoxy, and subliming salts. Their densities ranged from 4.9 to 81 lb per cu ft, and the thicknesses varied from 0.107 to 0.330 in. Swept-leading-edge models were fabricated from 30-lb per cu ft silicone-based ablators. The overlays were bonded to maintain the surface temperature of the base ablator below 500 F during ascent. Foams provided minimum-weight overlays, and subliming salts provided minimum-thickness overlays. Teflon left the most uniform surface after ascent heating.

Strauss, E. L.↗
NASA NTRS1978

Toxicity of pyrolysis gases from some cellular polymers

Various samples of cellular polymers were evaluated for toxicity of pyrolysis gases, using the screening test method developed at the University of San Francisco. The cellular polymer samples included polyimide, polymethacrylimide, polybismaleimide, polyurethane, polyisocyanurate, polyethylene, polychloroprene, polyvinyl chloride, polystyrene, polysiloxane, and polyphosphazene. The cellular polymers exhibited varying levels of toxicity under these test conditions. Among the rigid cellular polymers, times to death were shortest with the imide type foams and longest with polyvinyl chloride and polystyrene. Among the flexible cellular polymers, times to death were shortest with polyimide and polyester, and longest with polychloroprene and polysiloxane. Increased char yield was not necessarily associated with reduced toxicity.

Hilado, C. J.↗
NASA NTRS1989

A solution to water vapor in the National Transonic Facility

As cryogenic wind tunnels are utilized, problems associated with the low temperature environment are being discovered and solved. Recently, water vapor contamination was discovered in the National Transonic Facility, and the source was shown to be the internal insulation which is a closed-cell polyisocyanurate foam. After an extensive study of the absorptivity characteristics of the NTF thermal insulation, the most practical solution to the problem was shown to be the maintaining of a dry environment in the circuit at all times. Utilizing a high aspect ratio transport model, it was shown that the moisture contamination effects on the supercritical wing pressure distributions were within the accuracy of setting test conditions and as such were considered negligible for this model.

Gloss, Blair B.↗
NASA NTRS1993

Plastic Foam Withstands Greater Temperatures And Pressures

Improved plastic foam suitable for use in foam-core laminated composite parts and in tooling for making fiber/matrix-composite parts. Stronger at high temperatures, more thermally and dimensionally stable, machinable, resistant to chemical degradation, and less expensive. Compatible with variety of matrix resins. Made of polyisocyanurate blown with carbon dioxide and has density of 12 to 15 pounds per cubic feet. Does not contibute to depletion of ozone from atmosphere. Improved foam used in cores of composite panels in such diverse products as aircraft, automobiles, railroad cars, boats, and sporting equipment like surfboards, skis, and skateboards. Also used in thermally stable flotation devices in submersible vehicles. Machined into mandrels upon which filaments wound to make shells.

Cranston, John A.↗