Aeropan

PREFABRICATED AEROGEL BASED PANEL WITH SUPERIOR PERFORMANCE FOR BUILDING INSULATION

Today, the construction sector is the highest energy consumer in the EU (about 40%) and main contributor to GHG emissions (about 36% of the EU’s CO2 emissions). Thermal insulation materials are most important contributors to the decrease of energy demand in the building and life thin insulated panels with high performances are strongly requested.

This CIP-ECO innovation project aims the industrialization and first market application of a new fully recyclable prefabricated panel called AEROPAN which combines in one solution both clearly superior technical performance, faster in-building installation method that reduces time and cost and clear environmental benefits.
Specific innovations brought about in this project are:

1. The industrial development of AEROPAN. It consists of novel combination of Spaceloft ® with a coating thermoplastic composites plat that will allow realizing a self-sustaining mat owing total elimination of powders release that is a major bottleneck of aerogels. AEROPAN performance will be the same of Spaceloft (thermal conductivity <14 mW/m*K @ 10°C with only 10mm thickness and lifetime > 60 years).
2. The set-up of low-pressure molding process to produce the AEROPAN panel. This one-shot process will allow tuning the mechanical properties (e.g. flexural strength and elastic module) and the shape of AEROPAN panels by playing on the mold shape. The use of raw materials, GHG emissions and overall energy consumption is kept to the minimum. Water consumption is set to zero by eliminating water jet trimming. The expected regime production capacity is 2000 m2/day.
3. The implementation of an efficient in-building installation method (compliant with ETAG guidelines) that, owning the novel panel design, will allow reducing of the 80% the use of finishing materials (skim coats, anchors) and saving labour time and costs of 75%.

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