Highly Flexible, Fire Resistant HybridSil Foams for Next Generation Fireproofing, Insulation, and Energy Absorption NASA Applications

The objective of this Phase I STTR program is to adapt NanoSonic's HybridSil?nanocomposite technology for the creation of next generation highly flexible, fire resistant foams capable of extended operational lifetimes within demanding aerospace platforms. Phase I optimized nanocomposite foams would have immediate utility within a broad spectrum NASA applications as non-halogenated fire proofing, insulative, de-icing, and energy absorptive materials with tailorable breathabilities. To that end, NanoSonic and Dr. James McGrath's research group of Virginia Tech will work to design, optimize, and scale-up a family of highly flexible polyimide-polyorganosiloxane HybridSil?foams with statistically optimized cell content, mechanical durability, thermooxidative resilience, gas permeability, flexibility, and flame retardancy. This program will build from established non-halogenated, high temperature HybridSil?technology that has passed the ISO 9705 room corner burn test to obtain qualification as "fire restricting" per the International Maritime Organization, demonstrated a flame spread rating of zero (ASTM E-84), yielded thermal conductivities below commercially available polyurethane foams (<50 mW/mK), and elastomeric resilience (recovery from 1000 % deformation) from ballistic / blast impact threats . Rapid Phase III transition to commercial integration will be facilitated through an established HybridSil?pilot scale manufacturing infrastructure capable of producing>8,000 lbs. resin / day.