Cost-effective carbon insulation foams from waste tires
Transform waste tires into carbon insulation foams using a sustainable, cost-effective process without binders or catalysts. These foams feature excellent fire resistance, low density, and high thermal performance, offering an eco-friendly insulation solution.
Overview
The proposed solution leverages waste tires to produce carbon insulation foams, offering a sustainable and cost-effective alternative to traditional methods. By utilizing waste tires as the sole carbon source, this process eliminates the need for additional binders, catalysts, or foaming agents, significantly reducing production complexity and cost. The resulting carbon foams boast an open-cell structure, low bulk density, impressive thermal insulation (R-value of 7 or greater per inch), and Class A fire resistance ratings according to UL790 and ASTM E84 standards.
Technical specifications
The manufacturing process involves four key steps: grinding waste rubber tires into powders, molding the powders into blocks, foaming the blocks at 400–600 °C, and carbonizing them at 700-1100 °C. This method efficiently converts high carbon-content waste tires into lightweight, porous carbon structures with excellent thermal and mechanical properties. The foams' structural integrity is maintained by sulfur crosslinks inherent to tires, while the carbonization process enhances their fire resistance and thermal performance.
Technology readiness level
Currently at Technology Readiness Level 3, this technology has been demonstrated in a controlled laboratory environment. Future validation steps include optimizing fabrication conditions and characterizing the foams' structural, thermal, mechanical, and environmental properties to ensure high performance and sustainability.
About Syracuse University
Syracuse University is a comprehensive private research university in upstate New York, pairing fundamental inquiry with applied, industry-facing work. Industry engagement is anchored by a downtown innovation campus with co-located university–industry labs, pilot-scale testbeds, and flexible prototyping spaces. A centralized corporate partnerships office and experiential learning pipelines link R&D teams to faculty and student talent through sponsored research, internships, and capstone collaborations. Research is supported by competitive federal funding from agencies such as the National Science Foundation, National Institutes of Health, the Department of Energy, and the Department of Defense. A dedicated technology transfer office and campus-linked incubators streamline IP, licensing, and startup formation.
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