The
requirement of energy efficiency demands materials with superior
thermal insulation properties. Inorganic aerogels are excellent thermal
insulators, but are difficult to produce on a large-scale, are mechanically
brittle, and their structural properties depend strongly on their
density. Here, we report the scalable generation of low-density, hierarchically
porous, polypropylene foams using industrial-scale foam-processing
equipment, with thermal conductivity lower than that of commercially
available high-performance thermal insulators such as superinsulating
Styrofoam. The reduction in thermal conductivity is attributed to
the restriction of air flow caused by the porous nanostructure in
the cell walls of the foam. In contrast to inorganic aerogels, the
mechanical properties of the foams are less sensitive to density,
suggesting efficient load transfer through the skeletal structure.
The scalable fabrication of hierarchically porous polymer foams opens
up new perspectives for the scalable design and development of novel
superinsulating materials.