Adligenswil, Switzerland, April 2021 – Sekisui Alveo, European manufacturer of high-quality polyolefin foams, has developed a new product with low emissions, improved converting properties and good fire resistance. These qualities make Alveocel LP FR LVF ideal for a number of automotive applications. The material is particularly suitable for undershield absorbers, watershields, covers and other NVH parts.

Vehicle interior air quality has become a major issue amongst automobile manufacturers around the world. Plastic parts used in passenger compartments typically release volatile organic compounds (VOC) and condensable substances (FOG) that can be harmful to human health. That’s why car manufacturers demand materials with the lowest possible emissions and fogging values. Alveocel LP FR LVF fits that bill. It is a directly extruded PP foam that meets the automotive industry’s stringent requirements for low emissions as well as good fire resistance.

Certified compliant with automotive industry standards

To make sure the levels of VOCs present in vehicles do not jeopardise the interior air quality, car manufacturers throughout Europe have adopted the recommendations set forth in guidance document VDA 278, issued by the German Association of the Automotive Industry (VDA). Alveocel LP FR LVF meets these requirements as well as those of DBL 5455, VW 50180, and GADSL, the Global Automotive Declarable Substance List. The foam also shows good fogging behaviour as defined by DIN 75201-B: Determination of the fogging characteristics of trim materials in the interior of automobiles. This is the first direct extruded PP foam on the market that can meet all these norms and requirements.

Regarding VDA 270, Determination of Olfactory Properties of Automotive Interior Materials, Alveocel LP FR LVF is classified as Grade 3, which is considered adequate. The FR (fire resistance) in the name indicates that the foam complies with FMVSS 302, ISO 3795, as well as other flammability standards. Of course, the foam is also compliant with the applicable broader industry norms and requirements such as REACH and RoHS.

Ideal properties for automotive applications

The main applications of Alveocel LP FR LVF are in automobile manufacturing. Besides low emissions and good fire resistance, the material possesses good chemical resistance and heat resistance, ensuring durable performance. The new foam is ideal for watershields, undershield absorbers (box absorbers), and other NVH applications such as plugs and covers or insulation parts. Beyond the automotive industry, the new foam can offer advantages wherever off-gassing within enclosed spaces is an issue.

Improved conversion properties

Conversion methods for Alveocel LP FR LVF include thermoforming, die cutting, lamination, and welding. The vacuum-forming characteristics of the new material are excellent. The forming temperature is 140-150°C, which is significantly lower than that of the predecessor material. This means faster conversion, shorter cycle times, and lower energy consumption.

Thermal behaviour and physical properties

Alveocel LP FR LVF is a new non-crosslinked PP foam. It was developed as a refinement of Alveocel LP FR VF foam, and it shows improved performance in many aspects. Cold crack performance is significantly better compared to other products available in the market. High temperature stability remains adequate at 140°C.

The new foam has a smooth skin and fine cell structure. This is a distinguishing characteristic since most non-crosslinked PP foams have a coarse cell structure and a rough skin. The foam is slightly more flexible than other similar foams.

Product formats and versions

Alveocel LP FR LVF is a high-quality foam made of high-quality raw materials in the EU. The product is available in boards or rolls and can be delivered in densities ranging from 50 to 150 kg/m3 and in thickness ranging from 1 to 5 mm. The material is 100% recyclable.

Technical support for customers

Sekisui Alveo is well known for the strong customer support it provides. Specific customer requests require individual solutions. That's why Sekisui Alveo has been investing in its Application Service Laboratory (ASL) in Adligenswil for over 25 years. This competence centre allows the company to provide targeted support for customers in their technical projects and during the development of applications, including prototype production. The ASL is the only such facility in the sector within Europe and is a key to the innovation and quality advantage provided by Sekisui Alveo foams.