A new masterbatch technology for the use in XPS foam insulation panels is described. These new special additives make possible to obtain XPS insulation panels with lower values in thermal conductivity (λ value), increase in compressive strength properties and a better density profile across their thickness. All these properties are achieved by means of a reduction of the average cell size in the 25-65 % range as a consequence of the use of novel nucleating/reinforcing clay particles, which have a favorable interaction with CO2 blowing agent. Additionally, a new synergistic effect of a flame retardant organic molecule/clay is presented as a REACH compliant alternative to hexabromocyclododecane (HBCD). This new family of masterbatches is presented under the INNOVEX® trade registered name. The products here described are particularly focused on the insulation materials industry.

1. Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
A new polyfunctional flame retardant
masterbatch for XPS foam industry

2. A global producer of
performance
materials.
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

3. • Founded in 1919, Ferro is a leading,
global producer of performance materials
sold to manufacturers worldwide
• Our customers represent more than 30
industries 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
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

4. Founded in
1919
(Mayfield
Heights, Ohio)
4,600
employees
worldwide
23
countries
$1.8
billion
sales 2012
THE PERFORMANCE MATERIALS COMPANY

5. 5
 Engineered Polymer Materials
 Polymer Additives
 Performance Coatings (Tile Coating
Systems, Porcelain Enamel)
 Pharmaceuticals
Polymer and Ceramic Engineered
Materials Group

6. Engineered Polymer Materials Operations
Stryker, (NW) OH
72 Employees
Operating since 1980
Castellón, Spain
100 Employees
Operating since 1959
PLASTICS
CONFIDENTIAL

7. 7
Carpentersville, IL
35 employees
Operating since 1987
Belongs to Ferro since 1999
Plymouth, In
Gelcoat plant
32 employees
Operating since 1968
Engineered Polymer Materials Operations

8. 8
Engineered Polymer Materials Operations
Evansville, In
Filled and Reinforced Plastics
71 employees on site
Started as Complas in 1973
Belongs to Ferro since 1979

9. Master Batch Technology
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

10. XPS insulation industry
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

11. XPS Insulation Boards
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

12. Higher insulation capacity
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-
Hamburg

13. 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.
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

14. Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
INNOVEX
®

15. Advantages
HBCD
Free
Cell Size
λ reduction
CO2
Adsorption
Compr.
Strength
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

16. Cell Size
Talc MB INNOVEX
30-50% reduction
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

17. Morphological Study
Optical appearance
Innovex nucleated foam Talc nucleated foam
º
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

18. Cell size
(µm)
λ(W/m·
ºK)
Density
(Kg/m3)
Talc MB 132 0.0323 33
INNOVEX® 87 0.0291 30.6
λ reduction
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

19. 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
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
Compressive Strength
*1 Cell Anisotropy Ratio: Dgrav/ (Dext + Dwide + Dgrav)/3
*2 Cell Orientation Ratio: Dext/Dgrav

20. Solid state foaming with CO2
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
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).

21. 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
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
INNOVEX® produced an increase of 1.5% in the CO2 sorption when
compared to talc

22. FR Material
Br cont. (Kg
Br/100 Kg XPS)
Flame retardant
Test
HBCD 0.747 EUROCLASS E
INNOVEX® 0.544 EUROCLASS E
Flame Retardancy
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

23. Thermal Stability
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
the FFSB-0133 (typical masterbach with stabilized HBCD-red line) and FFSB-0388 (new Ferro
flame retardant masterbach –blue line)

24. Thermal Stability
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg
PS 0352 0133

25. 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.
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

26. CONCLUSIONS
INNOVEX® improvement in the cellular
structure produces a:
Reduction in λ .
An increase in the value of σ along the
thickness.
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

27. 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
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

28. 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.
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg

29. THANK YOU FOR YOUR
ATTENTION
jose.feijooj@ferro.com
Dr. José Luis Feijoo-Gómez
AMI Polymer Foam 2013
19 - 21 November-Hamburg