Demand for non-halogenated flame retardant additives to grow faster on environmental issues

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Demand for non-halogenated flame retardant additives to grow faster on environmental issues

Brominated flame retardants have excellent balance of performance, cost, properties and processability. However, concern regarding their use has compelled the industry to follow Government regulations and directives, as well as develop non halogenated flame retardant additives. Consumer and OEM preferences for more environmentally friendly materials have set the industry on a path toward alternatives like brominated and chlorinated additives broadly used for flame retardancy, especially in electrical and electronic applications.
Average �escape time� that a person has to get out of a burning home has dropped from 17 minutes in 1975 to only 3 minutes today, according to a study by Underwriters Laboratories released in October 2007. The UL study examined 27 combinations of materials now commonly found in homes, and found that synthetic materials produce hotter fires and more toxic smoke than natural furnishings. The higher fire load of consumer products and home decorations has effectively made home fires so dangerous that fire alarms sounding will often not provide adequate time for occupants to escape. The flame retardants for plastics therefore have become more critical than ever before. Increasingly stringent fire codes and flammability requirements, especially in building materials and consumer products, are driving demand for flame retardants steadily higher. In the US, the US$827 mln flame-retardant industry is expected to grow at an annual rate of 3% through 2011 as per Freedonia. Phosphorus-based types will grow the fastest, while brominated compounds will continue to lead the market in total value. Rapid gains are expected for smaller-volume flame retardants such as magnesium hydroxide, which is finding increased use in polypropylene and engineering resins. Alumina trihydrate (ATH) will remain the largest-volume flame retardant through 2011, comprising 45% of demand and growing in line with the whole market, the study says. Fast growth is expected for polyolefins and other thermoplastics such as engineering resins, which are increasingly used in FR construction and electronics applications. Slower growth is anticipated for PVC, polystyrene, and epoxy resins, Freedonia adds.
Ticona Engineering Polymers has been a pioneer in the development of non-halogenated flame-retardant thermoplastic polyesters (PBT), widely used in electronic and electrical equipment. European Union directives such as the Restriction of Hazardous Substances Directive (RoHS) and the Waste Electrical and Electronic Equipment Directive (WEEE) severely restrict the use of most brominated flame retardants in EE applications. Ticona first commercialized its Celanex XFR� range of flame-retardant thermoplastic polymers in 2006. Available in tilled and unfilled grades, the Celanex XFR series is formulated with a proprietary FR system that allows the material to be used as a "drop-in" replacement for most standard PBTs without having to modify designs or tooling. Celanex XFR grades are said to match the flow and toughness of Ticona's brominated FR series. A new enhanced series of Celanex XFR PBTs, designed for improved processability, are RoHS and UL94 V-0 compliant. The same FR system is also used in two new Pdteflex� XFR thermoplastic polyester elastomer (TPC-ET) grades, developed to help customers comply with anticipated hazardous substance restrictions and waste directives. With the introduction of Riteflex grades, Ticona has a variety of alternative engineering polymers that do not possess the controversial halogenated FRs. The company also offers Vectra� liquid crystal polymer (LCP) and Fortron� polyphenylene sulfide (PPS), which are inherently flame-resistant without the use of FR additives.
Prompted by a marked increase in the number of regulatory guidelines calling for the use of low-halogen and halogen-free flame-retardant products, PolyOne Corp. will provide sales and technical support in USA, Europe and Asia for its low-smoke and low-fume, zero-halogen (LSFOH) compounds. The company recently introduced Maxxam� FR polypropylene compounds, engineered to meet RoHS directives and further environmental legislation and stringent flammability requirements. The new PP grades are formulated to blend toughness and chemical resistance with low moisture absorption and improved mechanical and impact properties for an excellent cost-performance ratio, says PolyOne. The resins are available in compound and masterbatch forms in a range of colors. As a result of PolyOne's acquisition of GLS Corp., the company now offers an expanded portfolio, including OnFlex� S HF halogen-free, custom-formulated FR TPE-S compounds. Well suited for wire and cable insulation and jacketing applications, the compounds can replace conventional halogenated TPEs with no tooling rework or performance tradeoffs. Creating a halogen-free TPE has been a challenge because alternative flame-retardant additives can impact pliability and softness properties.
Bayer MaterialScience (BMS) has expanded its Makrolon� polycarbonate line with four new flame-retardant grades. Designed specifically for housings for televisions, computer monitors, and electrical applications, the new materials are free of antimony, chlorine and bromine, and they comply with the EU WEEE and RoHS directives. Makrolon 2467, 6357, and 6267 (opaque) are nonreinforced grades, while Makrolon 9417 is reinforced with 10% glass fibers. Bayblend� FR grades also conform to the EU directives. Bayblend FR3030 is a high-gloss, halogen-free sheet material made of a blend of PC/ABS. It offers excellent fire behavior and high impact resistance, and is well suited for thermoforming housings for electronics and television sets. Also well suited for the production of housings and a wide range of other products is Baydur� 66 FR, a versatile flame-retardant polyurethane that can be formed using RIM processes in inexpensive aluminum tooling.
RTP Company offers flame-retardant specialty compounds using over 40 different engineering resins. Among them are polypropylene in the RTP 100 FR Series for wire and cable jacketing, household appliances, and outdoor products; nylon in the RTP 200 FR Series for thin-wall molding of electronic and electrical connectors; and polycarbonate in the RTP 300 FR Series, offering superior impact strength, high heat resistance, and good electrical properties for business machines, housings, and consumer goods. RTP works closely with Underwriters Laboratories to certify a growing list of custom formulations that pass UL94 test parameters. For global customers, the company offers a family of halogen-free FR compounds that meet EU guidelines.
DuPont Engineering Polymers has developed new non-halogen FR grades of engineering thermoplastics for the electrical and electronic industry that meet UL94 V-0 rating requirements. DuPont Zytel� FR7025VOF and FR7026VOF unreinforced PA66 resins offer increased ductility and high tracking resistance (CTI) for appliance connectors. Zytel FR70G25NHV0 is a glass-fiber-reinforced PA66 with almost double the CTI of standard grades. For lead-free soldering applications, glass-filled Zytel FR7025NHV0 polyphthalamide provides high ductility, thermal stability, and electrical performance beyond the standard grades of Zytel HTN. Rynite� RE 19041 is a high-flow, non-halogen FR PET grade.
Albemarle Corp. offers a range of flame retardants to meet cost and performance needs for wire and cable, connectors, circuit boards, and enclosures for electronic and electrical applications. Albemarle Saytex� 102HP, a decabromodiphenyl ether (DecaBDE), was specially developed for electrical and electronic applications to comply with the European Restriction on the use of Hazardous Substances (RoHS) directive. It offers suitable performance for a wide range of plastics and often is the first choice as a low-cost, highly efficient (low loadings to reach high flame retardancy) flame retardant, notes Albemarle. The company also offers other FR products to meet specific application needs.
Among new FR products from Sabic Innovative Plastics is a line of Xtreme LNP Starflam� specialty compounds for electrical applications, designed to provide a lower-cost alternative to traditional materials such as thermosets and special high-heat polymers. Polyamide-based Starflam compounds provide halogen-free flame retardancy in an easy-molding compound. Also, new grades of LNP Faradex EMI/RFI shielding compounds are available with non-halogen flame retardancy. Based on PC/ABS alloys, the materials incorporate proprietary filler technology to improve the shielding ability of existing steel-fiber loadings. Compounds based on other resins are also available. The FR grades comply with the EU's WEEE and RoHS directives.
Huber Engineering Materials specializes in treated and untreated aluminum trihydrate (ATH) and magnesium hydroxide (MDH) grades for low-smoke, halogen-free flame retardants used in reinforced plastics, carpet backing, cast polymer, insulator, and wire & cable applications. Huber has developed a broad line of surface modifications to enhance the performance of ATH-filled compounds that aid processing and improve physical, electrical, flame, and chemical-resistance properties. Hymod� ATH, a treated grade, can enable higher loading levels-up to 70%-than untreated grades with similar particle-size distributions for applications requiring stringent fire-retardancy.
Ankerpoort N.V. of the Netherlands has introduced Securoc C10, an FR and smoke-suppressant filler based on hydrated calcium magnesium carbonate for use with chlorinated and plasticized polymers such as PVC and chloroprene rubbers used in cable compounds. The material is said to exhibit high electrical resistivity and an extended endothermic decomposition range, and reportedly is more cost-effective than ATH/MH.
Rit-Chem Co. is distributing Cellcom flame retardant products from South Korean manufacturer Kum Yang Co. in the US and Canada. They include smoke suppressants, char formers, and oxygen blockers. Among them are FR/ATO 50 alumina trihydrate, FR/ATO-10 antimony trioxide, FR/HMO-15 magnesium hydroxide, and FR/DBPE-50 and FR/HBCD. Rit-Chem is a sales agent for major U.S. and non-U.S. chemical producers.
Clariant's Pigments & Additives Division offers the Exolit line of phosphorus-based flame retardants in three product groups: ammonium polyphosphate-based Exolit AP, organic phosphorus Exolit OP, and red phosphorus-based Exolit RP. The Exolit� OP series of high-performance non-halogenated FR engineering plastics for electrical and electronics applications are colorless and easy to disperse, and they feature good rheological properties. Unlike conventional flame retardants, it has only a minor effect on the mechanical properties of the compounds. It has established itself as a proven flame retardant for fiberglass-reinforced polyamides 6 and 6.6. Exolit OP 1230 is a flame retardant with high temperature resistance that can be also used for high-temperature polyamides (HTN). Exolit OP 1240 was specially developed for thermoplastic polyesters (PBT and PET) used in combination with synergists in the injection molding of electronic components. The high-temperature resistance of Exolit OP935 makes it well suited for printed circuit boards, which must be processed in a lead-free solder bath. For compounds of polyolefins and reinforcing natural fibers such as wood/plastic composites, Clariant has developed Exolit AP 422.
Italmatch Chemicals of Italy has introduced Phoslite[R], its latest family of halogen-free FR additives for thermoplastic engineering polymers. Containing high phosphorus content, the material is said to be a highly effective flame retardant, characterized by high thermal stability, compatible with most organic polymers, nontoxic, and fully colorable. The additives are well suited for use in PBT, PC, and PC alloys, and in polyolefins and polyamides, says Italmatch. The company also produces the Masteret line of stabilized and polymer-bound red phosphorus masterbatches for electrical applications and the Melagard line of melamine-based FR additives.
Chemtura Corp. is a leading global producer of flame retardants, including Firemaster[R] bromine-based materials; Kronitex�, Reofos�, and Reogard� phosphorus-based materials; and Fyrebloc� flame retardants, among others. Chemtura recently introduced Fircmaster 600 and Firemaster 602 flame retardants for polyurethane foam. The FR products are said to be 10% more efficient than their predecessors, Firemaster 550 and 502. Each has an excellent environmental profile and is non-scorching in flexible PU applications in the automotive industry and in furniture manufacturing.
Albemarle has developed Antiblaze� 117HF, a halogen-free flame retardant designed to provide a safe and highly effective alternative to halogen-based FR products used in foams for furniture and automotive seating. Antiblaze 117HF is said to achieve the same protection as existing flame retardants, using up to 30% less product. It also provides excellent non-scorching performance, says the company. The product reportedly achieves the same protection and non-scorching performance as comparable flame retardants at lower loadings--up to 30% less.
Supresta, a specialist in phosphorus FR materials and other organophosphorus products, offers the Fyrol� line of tailor-made flame retardants for rigid and flexible foams. The company also offers the Fyrolflex� line for use with engineering resins for electronics and high-end structural plastics. Other Supresta FR additives serve as processing aids, lubricants, anti-wear materials, and wetting agents.
BASF's melamine resin foam, Basotect� UF, meets the latest EU standards for organic insulating materials for building construction and trains, the company reports. In Germany, Basotect UF, a thermoset foam, is rated as a construction material of "low flammability." Only inorganic materials in the noncombustible class perform better. The material, available in several formulations for various applications, exhibits high temperature resistance and good fire behavior. The material is lightweight, flexible, sound-absorbing, and thermally insulating. Victrex Manufacturing Ltd., headquartered in the U.K., recently announced that its PTIV� PEEK-based covering film meets the U.S. Federal Aviation Administration's new fuselage "burn-through" barrier requirement for new aircraft manufactured after Sept. 1, 2009. Lightweight thermal-acoustic-blanket-insulation systems using APTIV film are targeting conventional insulation systems that consist of fiberglass batting encapsulated in a plastic pillowcase covering. Produced from Victrex� PEEK� polymer, APTIV film provides low smoke and toxic gas emissions and is halogen-free, making it well suited for aircraft insulation and other interior applications.
Polyvel has introduced a new line of halogen-free, flame-retardant master-batches for engineering resins such as PC, PC/ABS, PPO, PET, and PBT. Predispersed in free-flowing pellets for improved efficiency, the new masterbatches are said to eliminate problems commonly associated with FR products, such as difficulties in handling high-viscosity liquids, low-melting-point solids, dust, and dispersion difficulties. Techmer PM is now offering an improved version of its PNM 13319 polyamide non-halogenated flame retardant concentrate. The carrier resin can be tailored more precisely to meet specific applications. Initially formulated for injection-molding applications, the new product is also suited for nylon profile extrusions. The concentrate, supplied as polyamide pellets, is intended to be processed at a temperature not to exceed 260°C (500°F). Techmer also offers PM13800 FR concentrate, which is said to pass the most stringent tests and can be used in all polyethylene films and for blow-molded and injection-molded parts, extruded low-density PE foams, extrusion coatings, and thermoformable sheet. O'Neil Color and Compounding has introduced new flame-retardant compounds, Faralloy� PE 401 and PE 405, for blow molding, extrusion, and rotational molding. Faralloy PE 405 is a low-cost compound with a UL94 V-0 rating at 1/4-inch thickness. PE 401 has a Melt Index of 4.5 and can be used in a wide variety of consumer and electrical applications, passing the more stringent UL94 5VA rating at 1/8-inch thickness. While it is more expensive than other flame-retardant compounds on the market, users can reduce the wall thickness and still meet UL flammability requirements, says O'Neil. The compounds are available in micropulverized and pellet form. The company also manufactures other FR grades of Faralloy compounds for a range of applications.
Sabic offers advanced PBT-based materials with specialized properties in flame-retardant grades, including Valox� Super High Flow glass-filled thermoplastic polyester resins and Valox ENH, PBT-based, environmentally friendly resins that meet the requirements for halogen-free parts. Sabic recently announced a portfolio of FR materials specifically for household appliance applications. The amorphous and semicrystalline materials offer a variety of properties, including flame retardancy without the use of brominated or chlorinated additives, meeting the EU directives.
DSM Engineering Plastics offers halogen-free FR grades of engineering thermoplastics in its Xantar C, Arnite XG, Akulon (Ultraflow) KFKMV5, and Arnitel C lines. Arnite T-XG 510 PBT, well suited for connectors in home appliance, is considered revolutionary because it is the first unfilled PBT that has achieved positive results on glow-wire testing for flammability. The lower density of the halogen-free PBT, compared with halogen-containing materials, is said to save material, cost, and weight. PBT also has better dimensional stability than moisture-absorbing materials.
BASF has upgraded its Ultramid� A3UG5 and A3X4G7 glass-filled FR polyamide grades to meet the rigorous International Electrochemical Commission (IEC) Household Appliance Standard. The halogen-free PA grades avoid the need for end-of-life dismantling of old appliances to recover plastics containing bromine flame retardants, which would be required under the EU's WEEE directive. Both materials provide good mechanical properties, especially toughness.
Lanxess AG offers an extensive portfolio of FR thermoplastic materials, including halogen-free grades of Pocan, which were among the first PBTs to achieve VDE certification to the IEC/EN 60335-1 standard for household appliances. Pocan is used in lamp sockets and a variety of other high-temperature applications. The company offers a line of halogen-free FR materials, including Disflamoll �, Levagard� and Bayfomox�. Disflamoll products are characterized by very good compatibility with polar polymers and can be compounded easily. They are suitable for a variety of polyurethane applications, in both rigid and fexible foam, and in coatings, adhesives, sealants, and elastomers. Levagard phosphorus FRs are well suited for rigid PU foams and construction applications. Bayfomox is a reactive dual-component PU system used to manufacture FR components for fire-stop applications in the construction industry.

A biobased plastic that is said to achieve the world's highest level of flame retardancy has been developed by Canon and Toray Industries. Called Ecodear�, it includes more than 25% plant-derived polylactic acid (PLA). It will initially be used in plastic parts for Cannon multifunction office systems, an application that has proved challenging for biobased plastics. Ecodear achieves 5V classification under the UL94 flammability-testing program, says Canon USA. Through continued technical development, Canon and Toray hope to achieve further enhancements in the field of biobased plastics, with the aim of expanding the range of target applications. NEC Corporation has developed a PLA composite reinforced with kenaf fibers that achieves high heat resistance and strength. The material currently is being used by NEC in mobile-phone components. The company reports that it also has added flame retardancy to PLA, without using toxic flame retardants. Another high-heat bioplastic innovation developed by NEC adds carbon fibers to PLA. The composite material is said to achieve higher heat conductivity than stainless steel. The company says it expects to reach volume production of bioplastic composites by the end of the 2009 fiscal year, when plans call for molding housings for electronic products from the materials. NaturalNano, a developer of advanced nanomaterials and additive technologies based on halloysite nanotubes (HTN�), is working on a variety of products with extended release properties, including flame retardants for furniture applications. Nanotubes, with their hollow structure, allow additives to be inserted into them to create a slow or extended release of the additive concentrate. For FR applications, NaturalNano believes that flame-retardant compounds can be developed that would release only under extreme heat.
Underwriters Laboratories, the independent product-safety certification organization, has encountered numerous instances where seemingly insignificant changes in a product's design, raw materials, or manufacturing processes have caused failure in fire-performance testing--even though the original product passed the tests and received certification. The key issue is to identify and understand which variables affect safety performance and which do not, says UL in a white paper, "Assessing the Impact of Variation on Product Fire Safety Performance." The UL94 flammability test is the most commonly referenced standard in the electrical and electronics sector. A wide array of testing services for every phase of the product design and product optimization process is available through UL Analytical Services. They include material characterizations, predictive analysis, root-cause failure analysis, and others. But, according to UL, whether a company conducts testing in-house or outsources it, a comprehensive program to assess and measure variation is crucial for meeting fire-safety requirements.
(Source Courtesy: Richard Stewart)