Scalable Rapid Fabrication of Low-Cost, High-Performance, Sustainable Thermal Insulation Foam for Building Energy Efficiency

Abstract

Bio-based thermal insulation materials offer a promising path towards energy savings in the buildings sector. However, these materials face competitiveness challenges against conventional petroleum-based alternatives due to issues with inferior insulation performance, poor compressive strength, and limited manufacturing scalability. Various fabrication methods such as freeze drying, thermal bonding, and chemical treatment have been proposed to enhance the material’s internal structure by introducing additional pores, creating a more complex path for heat transfer, and improving insulation efficiency. Despite advancements, the manufacturing scalability of these methods and their integration into industrial production remain unachieved.This thesis aims to bridge the gap between laboratory experiments and large-scale production by developing low-cost, sustainable cellulose-based thermal insulation. By investigating both aqueous and non-aqueous-based processing strategies, this work proposes several different fabrication techniques, leading to significant savings in energy, time, and cost. Establishing a comprehensive understanding of the interactions among the fabrication process, insulation foam, manufacturing scalability, and intended product application is imperative. This understanding accounts for variations in processing parameters (e.g., pretreatments, binders, temperature, time) and their impact on the insulation foam’s internal structure and overall performance. By examining the relationship between processing parameters and material structure, this thesis not only advances the fundamental understanding necessary for optimizing fabrication but also provides strategic guidance for selecting and designing scalable bio-based thermal insulation foams. Studying and characterizing commercially viable methods that seamlessly integrate with current industrial infrastructures is crucial for facilitating the transition from small-scale laboratory experimentation to large-scale industrial production. Through various technical strategies, this work illustrates how our understanding can be utilized to offer direction for fabrication method selection, design, and processing, ultimately optimizing the scalable rapid fabrication of low-cost, high-performance sustainable thermal insulation materials for building energy efficiency.