Flame retardant extruded closed cell foam

Improved flame retardant for extruded foams

Extruded Polymer Foams containing Easters of a Sugar and a Brominated Fatty Acid as Flame Retardant Additive.

Flame Retardant (FR) additives are commonly added to extruded polymer foam products that are used in construction and automotive applications. The presence of FR additive allows the foam to pass standard fire tests as are required in various jurisdictions. Various low molecular weight (<~1000g/mol) brominated compounds are used as FR additives in these foam products. Many of these such as hexabromocyclododecane, are under regulatory and public pressure that may lead to restrictions on their use, so there is an incentive to find replacement for them.

An alternative FR additive for extruded polymer foam should be capable of allowing the foam to pass standard fire tests when incorporated into foam at reasonably low levels. Because extruded foams are processed at elevated temperatures it is important that the FR additive be stable at the thermal conditions used in extrusion process. For some foams such as polystyrene and styrene copolymer foams, these temperatures are often 180 degree C or higher. Several problems are encountered if FR additive decomposes during extrusion process. These include loss of FR agent and therefore FR properties, and the generation of decomposition products (such as HBr) that are often corrosive and therefore potentially dangerous to humans and harmful to operating equipements. The FR agent should not cause significant loss of desirable physical properties in the polymer. It is preferable that the FR additive has low toxicity and is not highly bioavailable.

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