Adligenswil, Switzerland, August 2021 – Sekisui Alveo, European manufacturer of high-quality polyolefin foams, has expanded its portfolio of flame-retardant foams to include new halogen-free versions. The technical performance of these new foams remains virtually unchanged compared with their halogen-containing counterparts, but the potential impact on human health and the environment is significantly reduced. The new foams are thus ideal for use as components in sustainable end products.   

Plastics made of organic polymers are typically very flammable due to their high carbon content. Depending on their chemical composition, such materials can release toxic gases such as hydrogen cyanide or carbon monoxide when they burn. Many synthetic foams therefore incorporate flame retardants as a safety measure.

Drawbacks of standard flame retardants

The industry’s standard flame retardants include halogenated compounds like tris (1-chloro-2-propyl) phosphate (TCPP) or polybrominated diphenyl ethers (PBDE). These are effective as flame retardants but they have a drawback: They are allegedly harmful to health and the environment. Several of these substances are extremely persistent and accumulate in the environment, have hormone-like side effects, or are considered carcinogenic.
As a company committed to sustainability and environmental responsibility, Sekisui Alveo sought alternative ways of providing fire protection that avoid these hazardous side effects. The company has been successful in doing so, and recently expanded its broad product portfolio of high-quality foams to include new versions of flame-retardant foams that are halogen-free.

Innovative new formula

Sekisui Alveo is known for innovation in foam. In fact, the company was the first in the world to manufacture physically cross-linked polyolefin foams in roll form. Now it has developed a type of flame-retardant foam that contains no heavy metals or brominated or chlorinated components. Instead of these compounds, special halogen-free organic components are used. The physical properties of the product are virtually identical to those of halogen-containing flame-retardant foams. Thus, Sekisui Alveo has successfully replaced the detrimental flame retardants without compromising product performance.
The halogen-free flame-resistant versions are currently available for the product lines Alveolit TA and Alveolit TL in various densities and thicknesses. The halogenated versions of these foams currently remain available as well.

Successfully tested for automotive applications

In vertical fire testing, the new foam fulfils the specifications of standard EN 13501-1 for the classification of construction products and types of construction with regard to fire behaviour. In horizontal fire testing, the specifications of FMVSS (Federal Motor Vehicle Safety Standards issued by the American NHTSA) are met, so the new foams are perfectly suitable for automotive applications. Other potential applications include building construction, electronics, and appliances.
In flammability tests, the smoke gas emitted by the new foams shows a much lower conventional index of toxicity (CIT) than that of foams containing halogens or heavy metals. The smoke produced is white, which can simplify rescue operations.

Cradle to Cradle

The new foams are good news for manufacturers who intend to have their products certified by the Cradle to Cradle Products Innovation Institute. As a component, the foams can meet the requirements necessary to obtain a very good rating of the end product. Due to the absence of halogenic flame retardants and heavy metals, high requirements for recyclability are met and compliance with the category "Material Health" is achieved.

Click here to watch our product test video.