VOC-free, Highly Flame Resistant HybridsilTM Insulation Coatings for Next Generation Thermal Insulation and Energy Efficiency

The objective of this Phase I SBIR Program is to develop VOC-free, spray depositable HybridSilTM insulation coatings for providing next generation thermal insulation and energy efficiency within commercial and residential buildings. The proposed coating technology will serve as a replacement for currently employed polyurethane spray foam coatings yet provide orders of magnitude greater thermal insulation, environmentally friendly VOC-free spray deposition processes, validated flame protection, biofouling resistance, and superior mechanical durability. Upon deposition, NanoSonic’s HybridSilTM foams will expand within seconds to provide lightweight coatings that permeate wall cavities to provide thermal insulation and air sealing for the lifetime of the building structure, this reducing energy consumption while providing zero indoor air pollutants. This program will build from established non-halogenated HybridSilTM technologies that have passed ISO 9705 room corner burn test to obtain qualification as “fire restricting” per the International Maritime Organization (IMO), thermal conductivities below commercially available polyurethane foams (<50 mW/mk), elastomeric resilience (recover from 1000% deformation) and ballistic impact durability. To meet this challenge, NanoSonic will argument its high temperature HybridSilTM Nanoporous materials for use as low-cost, VOC free foams that may directly displace currently employed polyurethane foams, as well as have the capability of rapid integration using currently employed spray equipment. Rapid Phase III transition to commercial integration will be facilitated through an established HybridSilTM pilot scale manufacturing infrastructure capable of producing 8,000 lbs resin/day.