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Building insulation is a simple and effective way to save energy and contribute to climate protection
.
The next-generation flame retardant alternative is the sustainable, compatible polymeric flame retardant Emerald Innovation™ 3000
.
Emerald Innovation™ 3000 is a high molecular weight polymer consisting of triblock butylbenzene brominated copolymers
.
Table 1: Emerald Innovation™ 3000:
● Butadiene-styrene brominated copolymer
● High molecular weight>100,000g/mol
● Bromine content: 65%
● Softening point: 120°C(TG)
● Thermal stability: >250°C
One way to describe and evaluate flame retardant properties is the LOI, or Limiting Oxygen Index (ISO 4589)
.
In Figure 1, we compare the LOI values of HBCD and Emerald Innovation™ 3000 flame retardants for polystyrene extruded foam panels (XPS) containing the same bromine content, respectively
.
Figure 1: Fire performance test of polystyrene extruded foam board
The graph to the right shows the flame retardant performance of polystyrene foam panels using HBCD and Emerald Innovation™ 3000 flame retardants, respectively
.
The production of flame retardant polystyrene extruded foam panels is usually carried out in two steps
.
The first step is to add a flame retardant to the polymer carrier to prepare a flame retardant masterbatch
.
In the second step, flame retardant masterbatch is added in the final extrusion process to produce polystyrene extruded foam board
.
In order to successfully produce high-quality flame-retardant polystyrene foam boards, in the masterbatch processing (first step), the flame-retardant additives and other additives must be uniformly dispersed in the polymer carrier through an extrusion mixing process
.
Energy dispersive X-ray (EDX) imaging of composites is a method to determine the dispersion quality of additives in polymer binders
.
When producing Emerald Innovation™ 3000 masterbatches in polystyrene, this method is the method of choice to analyze bromine distribution and its image as long as Emerald Innovation™ 3000 is the only bromine-containing component in the compound
.
Figure 1: EDX Image - Dispersion Analysis of Emerald Innovation™ 3000 in a Polystyrene Matrix
In Figure 1, the red pixels are caused by bromine, so the distribution of bromine can be known
.
Figure 1A shows that the distribution of brominated flame retardants in polystyrene is not uniform, and its red pixel distribution has obvious differences, indicating that the brominated flame retardants are more concentrated in the upper left area
.
Figure 1B shows a uniform distribution of red pixels, indicating that the flame retardant Emerald Innovation™ 3000 is well dispersed in polystyrene
.
Good dispersion of flame retardants during masterbatch production will produce high quality Emerald Innovation™ 3000 PS masterbatches
.
With the addition of XPS extrusion process, high-quality flame-retardant polystyrene extruded foam sheets can be produced
.
Extruded polystyrene thermal insulation foam panels need to be produced according to these necessary conditions
.
The Jiangsu Institute of Product Quality Inspection conducted fire tests according to Chinese Standard 8624-2012 to evaluate the quality of polystyrene extruded foam panels produced with well-dispersed Emerald Innovation™ 3000 masterbatch
.
Table 2: GB8624-2012 standard combustion performance B1 (C) level
Table 2 describes the two test methods
.
The first two rows are for the Single Burn Item (SBI) test and the last two rows are for the small burner test
.
Column 2 lists the properties, column 3 shows the classification criteria for obtaining a combustion performance class B1(C), and column 4 gives the test results
.
The polystyrene extruded foam board used in these tests passed the requirements of GB8624-2012 B1(C) with excellent performance
.
Tests have shown that Emerald Innovation™ 3000 can produce high-quality XPS insulation that meets Chinese fire safety standards
.
If Emerald Innovation™ 3000 is selected as the next-generation flame retardant solution after December 25, 2021, it is necessary to improve the process and compound, especially the preparation process of the masterbatch and its thermal stability
.
