Enhanced thermal insulation performance polymer foam

Our concept concerns the development of an innovative high performance thermal insulation material that offers thermal conductivity and density approaching that of aerogels but at a cost that competes with PU and EPS foams. Polymer foam insulation such as polyurethane and expanded polystyrene (e.g. Styrofoam) is made by expanding the polymer with a blowing agent to produce a foam with relatively large cells that contain the low conductivity gas blowing agent. As the gas migrates out of the cells over time, the foam ages and the insulation performance falls. We will develop a polymer foam by a templating method to manufacture an insulation material with careful control of porosity and cell size distribution whilst eliminating the use of blowing agents; low thermal conductivity is achieved by high porosity and small cell size only. Proving the concept of the technology for enhanced thermal insulation manufacture will lead to a breakthrough innovation in the cost-effective and competitive production of high performance, blowing agent-free polymer foam thermal insulation material that can be used in a number of sectors where enhanced, reliable, low-cost thermal insulation is required, including refrigerated transport, construction, and hot water storage.