A new polyfunctionalflame retardant masterbatch for XPS foam industry

Dr. José Luis Feijoo-Gómez

AMI Polymer Foam 2013

19 - 21 November-Hamburg

A new polyfunctional flame retardant masterbatch for XPS foam industry

A global producer of performance materials.




• Founded in 1919, Ferro is a leading, global producer of performance materials sold to manufacturers worldwide

• Our customers represent more than 30industries and span 100-plus countries

• We have manufacturing facilities in the Americas, Europe and Asia-Pacific

• Ferro has more than 5,200 employees working at sites in 23 countries




Founded in

1919(Mayfield

Heights, Ohio)

4,600employees worldwide

23countries

$1.8

billionsales 2012

THE PERFORMANCE MATERIALS COMPANY

5

Engineered Polymer Materials

Polymer Additives

Performance Coatings (Tile Coating Systems, Porcelain Enamel)

Pharmaceuticals

Polymer and Ceramic Engineered

Materials Group

Engineered Polymer Materials Operations

Stryker, (NW) OH

72 Employees

Operating since 1980

Castellón, Spain

100 Employees


PLASTICS

CONFIDENTIAL

7

Carpentersville, IL

35 employees


Belongs to Ferro since 1999

Plymouth, In

Gelcoat plant

32 employees



8


Evansville, In

Filled and Reinforced Plastics

71 employees on site

Started as Complas in 1973

Belongs to Ferro since 1979

Master Batch Technology




XPS insulation industry




XPS Insulation Boards




Higher insulation capacity



19 - 21 November-

Hamburg

COUNTING DOWN

• HBCDD is a PBT molecule.

• UNEP lists HBCD as a Persistent Organic Pollutant

with temporary exemptions.

• Last day HBCD can be used: 21/08/2015.







INNOVEX®

Advantages

HBCDFree

Cell Size

λ reduction

CO2Adsorption

Compr.

Strength




Cell Size

Talc MB INNOVEX

30-50% reduction




Morphological Study

Optical appearance

Innovex nucleated foam Talc nucleated foam

º




Cell size

(µm)

λ(W/m·

ºK)

Density

(Kg/m3)

Talc MB 132 0.0323 33

INNOVEX® 87 0.0291 30.6

λ reduction




Materials σ

(KPa)

CAR*1 COR*2

Talc MB 350 1.1-1.2 0.6-0.8

INNOVEX® 440 1.3-1.4 0.4-0.6




Compressive Strength

*1 Cell Anisotropy Ratio: Dgrav/ (Dext + Dwide + Dgrav)/3

*2 Cell Orientation Ratio: Dext/Dgrav

Solid state foaming with CO2




Solid state foaming was carried out at laboratory scale at CellMat (University of Valladolid, Spain)

J.E. Martini-Vvendenskyand and N.P. Shu, US Patent 4473665 (1984).

Materials

Density

(Kg/m3)

Cell size

(µm)

%CO2

PS N2380 67 112 7.35

HBCD/Talc (C) 42 100 7.23

INNOVEX®/Talc 36 56 7.29

INNOVEX® (A) 32 69 7.35

CO2 Sorption




INNOVEX® produced an increase of 1.5% in the CO2 sorption when

compared to talc

FR Material

Br cont. (Kg

Br/100 Kg XPS)

Flame retardant

Test

HBCD 0.747 EUROCLASS E

INNOVEX® 0.544 EUROCLASS E

Flame Retardancy




Thermal Stability




the FFSB-0133 (typical masterbach with stabilized HBCD-red line) and FFSB-0388 (new Ferro flame retardant masterbach –blue line)

Thermal Stability




PS 0352 0133

CONCLUSIONS

The particles included in INNOVEX® act as novel

nucleating agent that improves the cellular structure

in terms of:

Reduction of the average cell size,

Increase of the anisotropy in the gravity direction.




CONCLUSIONS

INNOVEX® improvement in the cellular

structure produces a:

Reduction in λ .

An increase in the value of σ along the

thickness.




Finally

INNOVEX® FR includes non-PBT halogenated

flame retardant organic molecules that present a fire

retardant synergistic effect with the inorganic

particles.

This results in a REACH compliant alternative to

HBCD, also presenting a lower amount of Bromine

content.

Patent granted




Acknowledgments

I want to thank CellMat (University of

Valladolid) and especially Dr Miguel Angel

Rodríguez-Pérez for all the collaboration and the

foam characterization of the XPS foam samples.




THANK YOU FOR YOUR

ATTENTION

[email protected]




Environment

A new polyfunctionalflame retardant masterbatch for XPS foam industry