THE PROBLEM: A vacuum insulation panel (VIP) is a highly efficient thermal insulation material that is at least five times more effective at preventing heat transfer than typical building insulation materials. The material consists of a rigid, porous core encased in an impermeable barrier envelope from which ambient gases are removed, creating a vacuum. However, current VIPs are easily damaged and require careful handling, limiting their widespread use in construction. 

THE SOLUTION: Oak Ridge National Laboratory (ORNL) sought to improve VIP technology to encourage broader use, better insulation, and reduced energy demands, which supports the decarbonization goals of the Department of Energy (DOE). Residential and commercial buildings account for about 40% of the nation’s energy consumption. So ORNL developed a self-healing film that is applied to standard VIP cores to increase durability, ability to self-repair after punctures, shelf-life, and scalability. The film application is added to the existing manufacturing process and results in a high-performance insulation material that can be used in building construction. The film also allows for low thermal conductivity to improve energy efficiency, saving costs and facilitating long-term decarbonization goals. The technology is geared toward building insulation but has potential applications in the cold chain storage, automotive, food, pharmaceutical, and aerospace industries, as well as other building applications like pipe-wrapping and vibration reduction. 

THE TECH TRANSFER MECHANISM: Flexcon was chosen as a partner for ORNL’s self-healing barrier film for several reasons. Flexcon is an industry leader that can scale up production and accommodate manufacturing adjustments, and it has a dedicated pilot plant at its facility. A non-disclosure agreement (NDA) was established in 2019 and initial funding for the technology’s proof of concept was granted by DOE’s Building Technologies Office, allowing robust, advanced development that would be attractive to an industry partner. Flexcon signed a Cooperative Research and Development Agreement (CRADA) with ORNL in 2022. Later that year, patents were issued for the technology. In 2023, an exclusive R&D license was executed, securing Flexcon’s access to the patent and intellectual property (IP) and allowing it to research beyond the scope of the CRADA. 

THE TECH TRANSFER EXCELLENCE: The partnership began with an NDA to enable conversations. Winning a competitive Technology Commercialization Fund award from the DOE reinforced the technology’s viability, secured funding for development, and provided Flexcon the confidence to initiate a formal partnership through a CRADA and, eventually, an exclusive R&D license. This progression over more than four years showcases sustained commitment from both parties, with considerable forethought given to protecting and advancing the technology. The innovative and uncommon use of the exclusive R&D field of use license secured Flexcon’s access to the IP, allowing it to conduct research beyond the CRADA’s scope. This is vital for capitalizing on the technology’s potential and procuring additional IP and licensing opportunities. 

THE OUTCOMES: ORNL’s collaboration with a U.S.-based industry partner led to the development of an effective technology specifically tailored for commercial production in Flexcon’s U.S. facility using readily available, long-lasting, cost-effective materials. On-site testing provided further validation, resulting in a de-risked technology ideally positioned for economic impact in the U.S. and adoption in market sectors beyond the building industry. Although the self-healing barrier film for VIPs is not available commercially yet, the potential impacts of the technology’s widespread adoption in the building industry are compelling for DOE’s decarbonization goals.