Lead Performer: Oak Ridge National Laboratory – Oak Ridge, TN
Partner: GAF Materials Corp.
Total Funding: $2,000,000
DOE Funding: $1,600,000
Cost Share: $400,000
Project Term: October 1, 2021 – September 30, 2024
Funding Type: BENEFIT 2020 Funding Opportunity Announcement
Project Objective
Thermal insulation materials that achieve an R-value (i.e., thermal resistance, hxft2×°F/Btu) greater than 10/in. are of high interest due to their significant energy savings potential. However, to date, high-performance insulation materials are too costly and are thus relegated to niche markets. Oak Ridge National Laboratory (ORNL) is partnering with GAF Materials Corp., a major insulation material manufacturer in the United States, to combine their expertise and develop new high-performance foam insulation that will achieve an R-value ≥10/in. at low cost.
This project will use experimental data acquired by GAF and ORNL, state-of-the-art multiscale simulation tools, machine learning, and new knowledge in polymer synthesis and fabrication to develop novel designs for foam insulation materials that achieve this R-value without the use of vacuum. The project team will (1) select feasible designs based on industry experience on cost, durability, and other important aspects; (2) develop methods to process the selected designs; and (3) fabricate and evaluate new insulation materials. Both open-cell and closed-cell designs will be explored, with a preference for open-cell design that will not suffer from aging due to gas diffusion. If open-cell designs cannot achieve the target R/in., a closed-cell design with low thermal conductivity blowing agents will be used and diffusion-tight facers will be applied to minimize the aging.
The cost of this high-performance insulation will be justified by the high R/in. compared with state-of-the-art commercially available foam insulations on a $/ft2/R basis. The resulting foam insulation is expected to require minimal modifications to the current insulation materials manufacturing process. It will be suitable for building envelope applications that meet the construction industry's needs for durability, ease of use, and other code requirements. It can be used in new building construction and retrofit of existing buildings, which will lead to significant energy savings, especially in existing buildings that cannot meet code requirements because of space constraints.
Project Impact
The building construction industry is in need of high-performance insulation materials to increase building energy efficiency. Over seven Quads of primary energy consumption (approximately $70 billion in energy costs) in the United States was attributable to heat transfer through commercial and residential opaque building envelopes in 2010. A significant percentage of buildings in the United States are under-insulated, representing a significant market opportunity for the project’s low-cost, high-performance insulation in the country.
Contacts
DOE Technology Manager: Sven Mumme
Lead Performer: Som Shrestha, Oak Ridge National Laboratory