During the phase 1 period, Daren Labs focused its efforts on the market analysis and identification of a strategic path for the penetration and growth of LS-FR – based biopolymers. In order to reach effective conclusions, Daren Labs assembled a team of highly experienced industry experts for a week of intensive business-development brainstorming. The results of the market analysis showed that although eco-friendly biopolymer have significant market potential due to their eco-impact, their overall market share in the current polymer industry is currently only a fraction of a percent with only very slow market penetration expected in the next 10 year. With that in mind, it became clear that the real potential lays in improving currently-available semi-green FRs that are widely used in the plastics industry.
Based on their potential chemical-compatibility, it was proposed by the advisory board that the combination of Ammonium polyphosphate (APP), a non-halogenated FR commercially produced by Clariant (under the brand name Exolit) and our LS-FR might yield a new, lower cost, improved performance APP formulations. This would be a highly sought-after product with great market potential and environmental impact. The technical part of the Phase 1 focused on the development and testing of this new material.
The new “modified APP” (mod-APP) material was developed in Daren Labs in a process that is now in patent application process. The preliminary analytical testing of this new FR confirmed the initial estimations of improved thermal stability alongside strong intumescence – two well sought properties. Also, the low cost of the LS raw material impacts the overall cost of the mod-APP FR proportionally to its content (in the range of 20%-50%).
To confirm the feasibility of compounding, FR and mechanical properties of the mod-APP with Engineering Plastics, three commercial plastics where chosen for testing Poly Propylene (PP), Poly Amide 6 (PA6) and Polybutylene terephthalate (PBT).
Several kilos of the mod-APP were produced and sent to extrusion moulding at Aimplas Spain. During the compounding process several formulations were prepared for each plastic, then injected to produce FR burning and mechanical testing samples. These samples where then tested according to the UL-94 FR standard as well as for mechanical properties. The main conclusions of these tests are:
1. All three plastics are process-able with mod-APP
2. All three plastics showed similar FR performance compared to commercial APP
3. The mechanical properties tested of all three were not degraded compared to commercial APP
Additional experiments to fine-tune these formulations are already underway, however these promising results alongside the strong value proposition have already attracted the attention of three medium-small European compounders interested in becoming early-adopters for this new FR technology.
