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PolyUrethane-Clay Nanocomposite and Microcellular Foaming--Industrial Science and Technology Network, Inc., 1600 Pennsylvania Ave., York, PA 17404-1754; 717-843-0300
Dr. Roman Domszy, Principal Investigator
Dr. Arthur Yang, Business Official
DOE Grant No. DE-FG02-98ER82597
Amount: $750,000
A new interior thermal insulation will be developed by using a glass-blown process to imbed a novel morphology of microcellular polymer foam into the gallery between inorganic plate molecules. Homogeneous nucleation of gas embryos within the gallery of plates will be induced to control the pore size of the composite foam. The composite foam is expected to have exceptional mechanical, thermal, and diffusive properties, and additional chemical modifications will enhance its resistance to fire and smoke. In Phase I, cost-effective separation of clay molecules was achieved with the intercalation of polyol molecules. Polyurethane-clay nanocomposites were produced by the polymerization of the clay-polyol nanocomposite. Foaming of the polyurethane-clay nanocomposite was achieved by heterogeneous nucleation. In Phase II layered clay plates and submicron pore structure will be produced by foaming the polymer-clay nanocomposite under high-pressure or low interfacial tension. Novel surface treatment technology will be developed to promote homogeneous nucleation during gas foaming. Additional chemical modification of the base polymer will be used to further improve performance against fire and smoke.
Commercial Applications and other Benefits as described by the awardee: The property improvements resulting from the separated clay structure should lead to many novel applications of the composite foam material. Low-density microcellular foam of polyurethane-clay nanocomposite can be used to replace HCFC-blown insulation in refrigerators. New foam material with significantly improved fire and smoke retardancy is critically needed for retrofitting airplane insulation.