POLYSTYRENE FOAMING

PREPARED BY:
WE’AM ALMASRI 20712061

AMJAD ALSHAER 20710232

MOHAMMAD QASRAWI 20711283

INSTRUCTOR:
DR. RA’ED MA’ALI
1
STYRENE
 Its the product of a two-fold reaction, Ethylene and
benzene, in the presence of a catalyst such as aluminum
chloride, form ethyl benzene, which is then
dehydrogenated to form styrene.

ETHYLENE BENZENE STYRENE

2
 POLYSTYRENE
 Initiators thermally decompose, thereby forming active free
radicals that are effective in starting the polymerization
process. Typically initiators used in the suspension process
include benzoyl peroxide and others. Potassium per sulfate is a
typical initiator used in emulsion polymerizations. In the
presence of inert materials, styrene monomer will react with
itself to form a homopolymer POLYStyrene.

STYRENE STYRENE
MONOMER POLYSTYRENE
MONOMER 3
FOAMING:
BLOWING AGENTS:
 Any gas can serve as a blowing agent, but not every gas can be
easily implemented in the foaming process.

 The blowing agent’s quality, quantity, and nature are key

factors in the production of a foamed structure.

 Foam develops by agglomeration of gas bubbles in a melt. The

individual gas bubbles are hindered from assuming the
energetically favorable round form which are governed by the
polymer matrix,

4
 The cellular structure and the gas composition a gaseous phase is being dispersed in a spherical
form within a polymeric matrix, a composite structure is naturally formed, and the properties
of this composite are determined by its constituents and their distributions.

 Common foaming processes are the following:

1. Air is whipped into a dispersion or solution of the plastic, which is then hardened by heat or
catalytic action or both.

2. A low-boiling liquid is incorporated in the plastic mix and volatilized by heat.

3. Carbon dioxide gas is produced within the plastic mass by chemical reaction.

4. A gas, such as nitrogen, is dissolved in the plastic melt under pressure and allowed to
expand by reducing the pressure as the melt is extruded.

5. A gas, such as nitrogen, is generated within the plastic mass by thermal decomposition of a
chemical blowing agent.

6. Microscopically small hollow beads of resin or even glass are embedded in a resin matrix.

5
POLYSTYRENE FOAMS:
 Polystyrene is material that has properties such as light,
rigid, closed-cell plastic foams, having low thermal
conductivity and excellent water resistance, Therefore, the
polystyrene is widely used in the manufacturing of plastic
foams by two process injection and extrusion molding.

1. Extruded polystyrene foam.

2. Expandable polystyrene for molded foam.

6
EXTRUDED POLYSTYRENE FOAM (XPS):

 This material is made by extruding molten polystyrene

which is include a blowing agent , the process occurs
under elevated temperature and pressure into atmosphere
where the mass expands and solidifies into Desirable
form . the trade name Styrofoam . Which is Characterized
as lightweight material .

7
THE EXTRUSION POLYSTYRENE FOAM PROCESS
 By using two extruder to manufacture continuous length of foam.
 The first one melts and mix a dry blend of the polymer polystyrene and the additives
The process of (EXP) occurs in the following Sequence:

1. the process begins with polystyrene with solid polystyrene crystals .The crystals & ,special additives and a
blowing agent, are fed into an extruder.
2. Inside the extruder the mixture is blending and melting .Conditions of high temperature and pressure, into a
viscous plastic fluid. ”It is very important to get the suitable viscosity.
3. The hot, thick liquid is then forced in a continuous process through a die. As it emerges from the die it
expands to foam.
4. The thick liquid is shape, and it cools with suitable cooler systems. The last step in this process is to
finishing, and cutting the thick foam product.

8
EXPANDED POLYSTYRENE FOAM (EPF)
 EPF is a linear polymer whose basic unit is styrene , Is a plastic material that Composed of individual cells
of low density polystyrene ,and has special properties due to its structure, EPF consists of a polymer chain
with great molecular weight. A molecule's weight is equivalent to its mass.

 PS quality-molded blocks are used for many applications, it must be cut to a desired dimension and, this type
of foam is produced from beads containing a blowing agent . Thus, pellets taken from an ordinary melt
extruder or beads produced by suspension polymerization are impregnated with a hydrocarbon such as
pentane. The vapor pressure of the pentane dissolved in the polymer is low enough to permit storage of the
expandable polystyrene in a closed container at ordinary temperature and pressure. The expandable
polystyrene beads may be used in a tabular blow-extrusion process to produce polystyrene foam sheet.

 Expandable polystyrene beads are often molded in two separate steps:

1. Preexpansion or prefoaming of the expandable beads by heat
2. Further expansion and fusion of the preexpanded beads by heat in the enclosed space of a shaping mold.

Tabular Blow-Extrusion to produce low density polystyrene foam sheet 9

EXPANDABLE POLYSTYRENE PROCESS CONSISTS of THE
FOLLOWING STEPS
 PREPARING THE BEADS: The polymerization polystyrene consisting of beads made up of
polystyrene chains is cooled. These beads are then washed out and dried. Uniform bead size is achieved by
sorting the beads through meshes which filter out over- and undersized beads.
 MAKING EXPANDED POLYSTYRENE FOAM: First, the beads of polystyrene must be
expanded to achieve the proper density. This process is known as pre-expansion, and involves heating the
polystyrene either with steam or hot air. During pre-expansion, a device is used to keep the beads from
fusing together. Since expanded beads are lighter than unexpanded beads, they are forced to the top of the
vessel's cavity and discharged. This process lowers the density of the beads to three percent of their original
value and yields a smooth-skinned, closed cell EPF that is excellent for detailed molding. Next, the pre-
expanded beads are usually "aged“ this allows air to diffuse into the beads, cooling them and making them
harder.
 MOLDING: After aging, the beads are fed into a mold of the desired shape. Low-pressure steam is then
injected into and between the beads, expanding them once more and fusing them together. The mold is then
cooled, either by circulating water through it or by spraying water on the outside.
 CUTTING, BONDING, AND COATING: EPF is usually cut with common wood-I working tools,
which must be kept very sharp at all times to cut smoothly. It can also be bonded with adhesives that do not
destroy it

10
FIRE PERFORMANCE, SITE HANDLING
& STORAGE, AND ENVIRONMENT:
 FIRE:
1. Styrofoam extruded polystyrene products contain a flame retardant additive to inhibit accidental ignition
from a small fire source, if its exposed to an intense fire, may burn rapidly. Its products will melt when
brought into direct contact with high temperature heat sources.
 HANDLING & STORAGE:
1. Styrofoam extruded polystyrene products should be stored on a clean, flat surface in an area free from
flammable or volatile materials.
2. When large quantities of the boards are stored indoors it is recommended that the building be ventilated to
allow a minimum of two air changes per hour.
3. To avoid surface degradation, the boards should be protected from direct sunlight when stored for long
periods in the open.
4. Light colored plastic sheeting is a suitable protective cover, but dark or transparent materials should be
avoided as they may cause excessively high temperatures to develop underneath.
5. Solvent attacks may occur if the blue extruded polystyrene products are used in direct contact with
materials containing volatile components.
6. Care should be taken to protect the boards from flames or other ignition sources during storage.

11
APPLICATIONS:
1. Styrofoam extruded polystyrene was first used as a flotation material in life-rafts and life-
boats as it’s fully closed cell structure made it highly resistant to water absorption.

2. Styrofoam being regarded as the perfect thermal insulation material.

3. ROOFING: its excellent moisture resistance and thermal performance retention properties,
Styrofoam roofmate is the ideal insulation material for Upside-Down roofing.

4. WALLS: it’s considerably reduce energy loss through external walls of new and existing
buildings.

5. COLD STORES AND PANELS: Styrofoam is the ideal insulation for high-load-bearing floors
such as those found in cold stores, while its close tolerance, dust-free surface allows for
perfect bonding to a variety of sheet materials in high quality sandwich panels used in the
cold storage industry.

12
ADVANTAGES AND DISADVANTAGES
of EXTRUDED POLYSTYRENE FOAM
ADVANTAGES DISADVANTAGES
1. The major advantage of Extruded polystyrene 1. In case of a leak, repair procedures are more
foam surfboard blank is that it has a closed cell difficult.
structure. This makes is totally water repellent
2. There is only one choice for insulation
2. Extruded polystyrene foam is exceptionally panels: extruded polystyrene.
strong, and isn’t damaged as easily as EPS foam
by compressions. 3. Some quantities of water may be trapped
between insulation and waterproofing layer.
3. Extruded foam surfboard blanks will therefore
result in a faster and higher performance epoxy 4. Slopes should be created with utmost care.
surfboard. Allow for a slope of at least 2%. Preventively
increase calculated insulation thickness by 10%.
4. The waterproofing layer is not exposed to UV
radiation, other kinds of solar radiation and other 5. Ballast weight may not be acceptable for static
atmospheric factors of aging. It’s perfectly reasons
obvious and expected that its functional life will
be considerably longer.
13
ADVANTAGES AND DISADVANTAGES of
EXPANDED POLYSTYRENE FOAM
ADVANTAGES
 Has no impact on people´s health.
 Expanded polystyrene insulation
installation is very easy.
 Can be molded or any other way
shaped.
 Waterproof and resistant against
all in water dissolvable stuff.
DISADVANTAGES
 The foam polystyrene insulation is
not resistant against organic
solvents.
 Cannot be used in combination
with MPVC hydro-insulation foils.
 Can cause irritation of the eyes,
nose, and respiratory system;
headache, fatigue, dizziness,
confusion, drowsiness, weakness,
unsteady gait; possible liver injury
14
15