Polybenzoxazine Aerogels for Insulation in 38% Oxygen Environments

The proposed work will develop aerogels for insulation based on novel polybenzoxazine resins that exhibit ultra-low flammability in high oxygen concentration environments. These aerogels are designed to provide thermal insulation in high oxygen concentration environments up to 38% vol oxygen. Flame resistance will be provided through the molecular design of the polybenzoxazine structure. The molecular structure of the polymer and the microstructure of the material are both specifically designed to achieve three critical performance characteristics: ultra-low flammability, excellent, thermal insulation, and very low density. This directly targets the need for materials suitable for service in exploration environments where the oxygen concentration may be as high as 38% vol due to habitat, cabin, and vehicle environment optimization. This proposal highlights an aerogel microstructure structure most suitable for thermal insulation applications. However, the ultra-low flammability polybenzoxazine is anticipated to have additional applications such as acoustic barriers, packaging, panels, and other slab, sheet, film, and molded applications. This approach provides a path towards addressing the needs for materials that can perform in high oxygen environments. Performance will be evaluated using NASA-STD-6001B Test 1 Upward Flame Propagation at 38% vol oxygen.

The polymers and aerogels described in this proposal are specifically targeted to solicitation topic H3.13 for use as ultra-low flammability aerogels for thermal insulation in high oxygen concentration envoronments. Such materials, and variations thereof, have a multitude of potential NASA applications, including habitats, cabins, and vehicles. NASA has a compelling need for non-flammable materials in many different environments with oxygen concentrations ranging from 20% to 40%. The ultra-low flammability materials proposed here would be useful through the entire range, not just on the high oxygen concentration end. The proposed multifunctional materials, and potential variations thereon, address several enabling technologies and needs identified in NASA’s 2024 Technology Taxonomy document. Specifically, our proposed novel materials address needs in the following technology areas: • Habitation Systems (TX06.1.4) • Decompression Sickness Mitigation (TX06.3.8) • Fire Detection, Suppression, and Recovery (TX06.4.2) • Lightweight Structural Materials (TX12.1.1) • Materials for Extreme Environments (TX12.1.4) • Special Materials (TX12.1.7) • Lightweight Concepts (TX12.2.1) • Insulation and Interfaces (TX14.2.4) There is currently, and will continue to be for many years, a strong need for non-flammable materials in a wide range of commercial and construction applications. The large volume market opportunities that best match the targeted properties of the proposed materials are in aircraft and vehicles. The proposed materials would be most useful in commercial aircraft, military aircraft, warships, automobiles, and flying cars. Specific examples of targeted applications include panels or gap fillers for thermal insulation and/or acoustic insulation. Initial adoption of these novel materials will be in applications where the superior performance characteristics of ultra-low flammability and low density are highly valued, allowing displacement of existing materials. The markets for non-flammable materials in aircraft and vehicles are growing rapidly due to safety concerns and regulations. The market value of the global aircraft insulation industry was estimated to be $ 7.5B in year 2024. The growth rate is expected to be in the range of 8% to 9% annually for the next ten years due to rapid growth of aircraft manufacturing. Foamed plastics such as polyurethane and polystyrene are currently widely used. Improved materials that provide for weight reduction, better thermal insulation, and better acoustic insulation are sought to replace existing materials. Passenger comfort is an important driver due to desire for improved temperature control and noise reduction. A variety of more advanced materials that provide superior performance are vying to replace these. Aircraft insulation is the most promising non-NASA market for the proposed materials due to the high value of ultra-low flammability and reduced weight.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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