Fireproof PPE beads expand foam application sphereFireproof PPE beads expand foam application sphere
Automotive and electronics are top of the list for potential applications of a new expanded bead grade of modified polyphenylene ether (mPPE) recently developed by Asahi Kasei Chemicals Corp. (Tokyo).
June 17, 2011
The supplier says UL 94 V-0 rating and heat deflection temperature (HDT) of some 90°C with a foam expansion ratio of to 10 times will usher in completely new markets for foam materials for its SunForce expanded mPPE beads. The HDT of expanded polypropylene (EPP) beads, generally considered to have good heat resistance among foam materials, is only around 60°C under the same conditions.
The small diameter SunForce beads are said to feature excellent moldability, thus enabling formation of complex shapes, even with thin-walled portions, with high uniformity. SunForce also employs an eco-friendly, nonflammable inorganic gas as the foaming agent. In contrast, flammable hydrocarbons such as butane and pentane are generally used as foaming agent in conventional expanded beads. SunForce beads employ the company's Xyron mPPE resin in a non-halogenated formulation.
In the electronics industry, adoption of foam moldings has not progressed according to Asahi Kasei. This is largely due to the inadequate flame retardance and heat resistance performance of available foam materials, and in particular the unavailability of any foam material achieving the UL 94 V-0 rating which is essential for many electronic parts. Asahi Kasei is positioning SunForce as a promising material for use in electronic components such as ventilation ducts and fan holders, and as a substitute for metal chassis, such as for computer motherboard mounting and HDD holders).
In automotive, the supplier sees opportunities in insulated battery covers for hybrid-electric and electric vehicles, base materials for instrument panels, door panel backing boards, and deckboard core materials. Another focus area is home fixtures, where power supply covers and thermal insulation for water heaters are potential applications.
Trial marketing of SunForce will begin in October 2011, and full-scale production and sales are scheduled for fiscal 2012.The sales target for fiscal 2015 is ¥2 billion ($24.8 million).-[email protected]
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