PFAS-free Flame-retardant Plastic Can Incorporate More Than Half PCR Content

South Korea’s LG Chem reports that it has developed a PFAS-free flame-retardant polycarbonate (PC) and acrylonitrile-butadiene-styrene (ABS) blend made largely from recycled materials.

The combination of PC and ABS significantly enhances heat and abrasion resistance, said LG Chem, and the material has received the V0 rating in the standard UL 94 flame-retardant test for certification in the United States. 

The V0 rating is the highest level of flame-retardant performance in the industry, meaning the material will extinguish within 10 seconds when a flame is applied vertically. LG Chem said it is the first company to certify a V0 level or higher flame-retardant performance with a PFAS-free PC/ABS material.

"Forever chemicals" in the crosshairs

Per- and polyfluoroalkyl substances (PFAS) represent thousands of chemicals that have been widely used in a range of consumer products because of their heat resistance and other properties. They are also non-compostable and persistent in nature, hence the moniker of “forever chemicals,” and there is increasing demand for PFAS-free materials, especially in Europe and the United States.

Some analysts also predict a wave of class-action lawsuits could be in the offing in the United States, another reason for chemicals companies to develop PFAS-free alternatives and for brands to adopt them.

PCR material reduces carbon emissions

In addition to enhancing heat resistance of the PFAS-free material through a proprietary flame-retardant process, LG Chem said the inclusion of post-consumer recycled (PCR) material reduces carbon emissions. Over half of the material composition is made from recycled plastics, resulting in a 46% reduction in carbon emissions compared with standard PC/ABS materials.

LG Chem expects the material to be used in a range of applications, including electronic devices and electric vehicle chargers. In addition to PC/ABS, LG Chem has been successful in developing and obtaining UL certification for other PFAS-free flame-retardant materials, including PC and PBT.

Trinseo markets PFAS-free PC/ABS in Asia/Pacific

In a related announcement and as reported in PlasticsToday in April, Trinseo unveiled its line of PFAS-free flame-retardant PC and PC/ABS materials at Chinaplas 2024 in Shanghai. Also available with a percentage of recycled content, the Emerge resins are currently available in the Asia-Pacific market.