Thermal insulation properties

Fillers are different from additives, in the sense that they are only mixed with the polymer matrix to impart specific physical properties instead of chemical properties such as mechanical strength, electrical conductivity or dielectric properties, thermal insulation and they never take part in the macromolecule chain. Because fillers together with the polymer matrix are considered as composite materials they will be discussed in detail in the corresponding chapter. The major categories of filler, with some example, are however given briefly here ... 

Steam-Chest Expansion. In steam-chest expansion the resin beads in which gas is already present are poured into molds into which steam is injected. The steam increases the temperature close to the melting point and expands within the stmcture to create beads with food cushioning and insulating properties. Expanded polystyrene is widely used in this process for thermal insulation of frozen food packaging. 

Although thermal performance is a principal property of thermal insulation (13—15), suitabiHty for temperature and environmental conditions compressive, flexure, shear, and tensile strengths resistance to moisture absorption dimensional stabiHty shock and vibration resistance chemical, environmental, and erosion resistance space limitations fire resistance health effects availabiHty and ease of appHcation and economics are also considerations. 

Table 1. Typical Properties of Cellular Plastic Materials Used as Thermal Insulation...

Moisture. Absorbed and retained moisture, especially as ice, has a significant effect on the stmctural and thermal properties of insulation materials. Most closed-ceU plastic foams have low permeance properties most notably where natural or bonded low permeance surface skins exist (29,30). Design, building, and constmction practices requite adequate vapor retarders, skins, coatings, sealants, etc, in order to prevent the presence of moisture. However, moisture vapor cannot be completely excluded, thus the possibiUty of moisture absorption and retention is always present. The freezing of moisture and mpturing of cells result in permanent reduction of thermal and stmctural performance. 

The main use of lead metaborate is in glazes on pottery, porcelain, and chinaware, as weU as in enamels for cast iron. Other appHcations include as radiation-shielding plastics, as a gelatinous thermal insulator containing asbestos fibers for neutron shielding, and as an additive to improve the properties of semiconducting materials used in thermistors (137). 

Mechanical Properties. The physical properties of a particular refractory product depend on its constituents and manner in which these were assembled. The physical properties may be varied to suit specific appHcations. For example, for thermal insulations highly porous products are employed, whereas dense products are used for slagging or abrasive conditions. 

Polyurethane. Polyurethanes (pu) are predominantly thermosets. The preparation processes for polyurethane foams have several steps (see Urethane polymers) and many variations that lead to products of widely differing properties. Polyurethane foams can have quite low thermal conductivity values, among the lowest of all types of thermal insulation, and have replaced polystyrene and glass fiber as insulation in refrigeration. The sprayed-on foam can be appHed to walls, roofs, tanks, and pipes, and between walls or surfacing materials directly. The slabs can be used as insulation in the usual ways. 

Epoxies. The unique chemical and physical properties such as excellent chemical and corrosion resistances, electrical and physical properties, excellent adhesion, thermal insulation, low shrinkage, and reasonable material cost have made epoxy resins (qv) very attractive in electronic apphcations. 

Thermal Properties. Thermal properties include heat-deflection temperature (HDT), specific heat, continuous use temperature, thermal conductivity, coefficient of thermal expansion, and flammability ratings. Heat-deflection temperature is a measure of the minimum temperature that results in a specified deformation of a plastic beam under loads of 1.82 or 0.46 N/mm (264 or 67 psi, respectively). Eor an unreinforced plastic, this is typically ca 20°C below the glass-transition temperature, T, at which the molecular mobility is altered. Sometimes confused with HDT is the UL Thermal Index, which Underwriters Laboratories estabflshed as a safe continuous operation temperature for apparatus made of plastics (37). Typically, UL temperature indexes are significantly lower than HDTs. Specific heat and thermal conductivity relate to insulating properties. The coefficient of thermal expansion is an important component of mold shrinkage and must be considered when designing composite stmctures. 

Naturally, not all of these properties are improved at the same time nor is there usually any requirement to do so. In fact, some of the properties are in conflict with one another, e.g., thermal insulation versus thermal conductivity. The objective is merely to create a material that has only the characteristics needed to perform the design task. 

Laminated composite materials consist of layers of at least two different materials that are bonded together. Lamination is used to combine the best aspects of the constituent layers and bonding material in order to achieve a more useful material. The properties that can be emphasized by lamination are strength, stiffness, low weight, corrosion resistance, wear resistance, beauty or attractiveness, thermal insulation, acoustical insulation, etc. Such claims are best represented by the examples in the following paragraphs in which bimetals, clad metals, laminated glass, plastic-based laminates, and laminated fibrous composite materials are described. 

The toughness of a material is a design driver in many structures subjected to impact loading. For those materials that must function under a wide range of temperatures, the temperature dependence of the various material properties is often of primary concern. Other structures are subjected to wear or corrosion, so the resistance of a material to those attacks is an important part of the material choice. Thermal and electrical conductivity can be design drivers for some applications, so materials with proper ranges of behavior for those factors must be chosen. Similarly, the acoustical and thermal insulation characteristics of materials often dictate the choice of materials. 

This chapter will deal primarily with thermal insulation. Acoustic and fire-protection properties and applications will be treated as subsidiary to the thermal insulation aspects. 

The manufacturers and their suppliers are actively seeking alternatives, and some CFC-free polyurethane is already appearing on the market. However, these new products do not have such good insulating properties (thermal conductivity of the order of 0.03 W/mK is being quoted, as against the 0.02/0.025 W/mK of the originals). 

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