additives | Polymer foam
Right: AGC Chemicals
Americas has introduced Fluon Fluori-
nated Ethylene Propylene (FEP) foam
concentrates for LAN and
coaxial cable insulation
be considered as a cost reduction element but now the industry is looking for other technological advantages such as easier mould fill, specific density control and faster cooling, says Spier. “We recognised an increasing demand for endother-
mic foaming agents based on polystyrene or PLA for applications such as food packaging. Other problems needing new solutions are products containing high amounts of inorganic fillers. In addition, recent legisla- tive changes have not yet reached their final stages and many producers continue to use ADC-based foaming agents, mainly because there is no comparable substitute on the market. We are now offering to replace ADC with endothermic blends where high gas yield is required mainly due to the cost-benefit ratio. Some adjustments in the production process have to be made in order to complete the changeover, such as using a side feeder for foaming agent let-down, or different cooling systems. For replacing low gas yield ADC we are now offering expendable microsphere grades that are easier to control but require longer processing time in order to achieve high accuracy,” Spier says. Other developments on the horizon at Tosaf include a PLA-based foaming agent, as well as low temperature decomposition foaming agents for PVC and PE applica- tions where customers want to continue to work with ADC-based foaming agents. The decomposition temperature of these products is 150-160˚C. Future developments that the company is currently working on include foaming agents for engineering polymers and a line of universal foaming agents suitable for a broad range of applications and polymers.
Wire and cable Reducing weight remains a priority across a wide spectrum of markets and applications, according to Barto du Plessis, General Manager, PolyOne Colorant Chromatics. “Cost and raw material reduction have been key drivers behind the development of foaming technologies in industries such as automotive and
Right: Fraun- hofer Institute for Chemical Technology (ICT) uses a
Schaumtandex ZE 30/KE 60
laboratory line for research in technical
plastic foams
aerospace,” he says. “Performance benefits in niche applications are also driving innovation in foaming technologies. If we look at wire and cable applications, effective foaming technology can improve the electrical properties of the final product.” He identifies fluoropolymer foaming as an area of some activity. “Fluoropolymers are often used for highly specialised applications where processing is more complex than engineered polymer or thermoplastic processing. Melt and processing temperatures vary significantly and often speciality equipment is required to protect against corrosion. These challenges have limited the use of chemical foaming agents. OEMs have relied on physical foaming equipment and often avoided foaming certain fluoropolymers altogether.” PolyOne’s Colorant Chromatics business has
developed CFA-based foaming technologies for PVDF, FEP and other high temperature polymers. “These solutions enable manufacturers to enjoy the cost savings of lower raw material consumption and the performance benefits, without needing to invest in physical foaming equipment,” says du Plessis. “There is also far greater flexibility to differentiate with different high temperature polymers. CFA formulations are available in pellet form that can be added directly to the extrusion process. For greater flexibility, colour masterbatch can be added separately to the process or a pre-coloured foaming masterbatch can be supplied.” According to du Plessis, the initial application sector
for this new foaming technology has been wire and cable jacketing, especially where thin wall construc- tions are present and a combination of lightweighting and improved electrical properties are required. He says the technology can reduce density by up to 45% without compromising performance. AGC Chemicals Americas has introduced Fluon
Fluorinated Ethylene Propylene (FEP) foam concen- trates for LAN and coaxial cable insulation. The company says that when coated with foamed insulation produced from Fluon FEP concentrates, cables demonstrate minimal distortion and signal loss, and
46 COMPOUNDING WORLD | January 2016
www.compoundingworld.com
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