Environmentally Attractive Composite Panel Foam

In keeping with the long tradition of innovation, IFS has recently introduced a new range of insulation foams. Forming part of the well-known Envirofoam range of products, the new materials set a new standard in strength, thermal performance and environmental credentials. These products are ideal for the manufacture of building panels including conventional composite panels, cold-room panels and SIPs (Structural Insulated Panels).

It is well known that IFS introduced the very first CFC-free polyurethane insulation material in the late 80's, well ahead of the competition. The company then steadily improved its' product range with the introduction of "low GWP foams" and foams based on Natural Oil Technology. The latest developments, which are suitable for all composite panel applications, take the attributes to even greater levels of performance and environmental acceptability.

The NFG range of products is suitable for the manufacture of composite panels using either a discontinuous or a continuous production method. Rigid-faced building panels have been manufactured using this technology and have shown the following technical and environmental improvements compared with conventional foam systems:

Taking advantage of the pioneering work of the early 90's, which was summarised in a paper given at the 1994 UTECH Conference, Singapore, IFS has further developed the use of polyols derived from a natural, renewable source of chemical raw material. The polyol is derived from rapeseed oil and is manufactured in Norfolk from locally-grown crops. The one-step, low energy, conversion process results in the production of a polyol designated as Enviropol R201. This product is combined with conventional polyols to produce a material suitable for the production of a high-performance insulation foam. Third party verification of the environmental attributes of this product has been obtained from a specialist laboratory, Beta Analytics Inc.

The NFG range of products includes grades of differing fire performance characteristics. These range from a B2 polyurethane, a B2 PIR foam to a high-index PIR suitable for the most demanding applications. The first two products can be manufactured on either a discontinuous or a continuous foaming line. The high-index (350) PIR foam needs to be produced on a continuous line. All products exhibit good green strength, low thermal conductivity, fast production rates and excellent dimensional stability.

IFS introduced the first insulation foam with a Global Warming Potential (GWP) of “less than 5” in 2001. The latest development has resulted in a GWP of "less than 1", again ensuring that IFS remains well ahead of the competition in environmentally-attractive options.

A further important enhancement to this range is the introduction of the IFS Microcellular Technology, first introduced in 2003 as a means of further reducing the thermal conductivity of insulation foams. This technology results in an improvement of about 2mW in standard thermal conductivity tests. This can have a marked effect on the in-place performance of insulation both in building and refrigeration applications.

Taken individually, the attributes described above are important in the development of newer, high-performance materials. Taken all together, they represent a very significant contribution to the insulation industry as a whole.

Whilst the performance and environmental benefits described are very significant, it is also necessary to be able to provide these materials at a realistic price, in line with prices for conventional materials. Thanks to significant support from certain raw material manufacturers, IFS is able to accomplish this. It is also important to be able to provide a first-class technical support service to the customer, something that IFS has been able to do as a result of their highly experienced support staff.

Typical Systems within the Envirofoam NFG Range of Products