Biobased Foam Combines Insulation With Halogen-Free Fire Protection
Researchers at the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE are developing insulation foams that combine a partly bio-based material base with halogen-free fire protection. The CircularInFoam project focuses on polylactide (PLA) as an alternative to conventional fossil-based insulation materials for façades and buildings.
The research addresses several requirements at once, including thermal performance, fire safety, industrial production and compliance with regulations. It also explores how insulation foams could fit more readily into circular material systems.
Research Across The Material Chain
Three Fraunhofer institutes contribute expertise from different stages of development. Fraunhofer LBF develops modular, halogen-free flame-retardant systems based on oxyimides and sulfones. Fraunhofer ICT studies whether the formulations can be processed and foamed at an industrial scale. It also examines how production affects the foam’s mechanical properties.
Fraunhofer IBP assesses thermal performance and the suitability of the materials for future insulation applications. This work includes testing whether the foams release hazardous substances when they come into contact with water.
The researchers add the flame retardants through masterbatches: concentrated mixtures that manufacturers can blend into a base polymer during production. This modular method could help producers adapt the formulation to different products and processes while continuing to use existing production equipment.
Early Fire And Thermal Results
Initial tests with expanded PLA, or EPLA, indicate promising fire behaviour, although further research is needed to improve its classification and performance. The project has also developed and tested halogen-free flame-retardant formulations for expanded polystyrene systems.
According to Fraunhofer CCPE, the thermal conductivity achieved so far is comparable with established expanded polystyrene insulation standards. This suggests that the new foams could offer competitive thermal performance, but the materials remain in development and have not yet reached commercial application.
Replacing halogen-containing flame retardants may help reduce some environmental and health concerns associated with insulation materials. However, the overall impact will depend on the final formulation, production method, service life and end-of-life options.
Towards Industrial Application
The next stages will include demonstrators, more extensive fire testing and pilot production with industry partners. Fraunhofer CCPE is also exploring licensing and technology transfer for the flame-retardant and masterbatch systems.
For architects and material specifiers, the research points towards insulation products that could combine renewable feedstocks, fire performance and compatibility with established manufacturing processes. Further testing will determine whether these systems can meet the technical and regulatory demands of building applications at scale.
Source & photo: Fraunhofer CCPE