In the Dow Jones Sustainability World Index, DSM is listed as one of the leaders in the chemical industry sector. Within the Performance Materials cluster of DSM, DSM Engineering Plastics has launched an entirely “Green Portfolio” of engineering materials for new halogen-free applications. The development of halogen-free engineering plastics grades meets customer requirements and is in line with DSM’s sustainability policy (People, Planet, Profit). In this DSM states that the company sets out to use energy and raw materials efficiently in order to reduce the environmental impact of its activities and to improve the eco-efficiency of its products and processes on an ongoing basis.

Jos Goessens, President DSM Engineering Plastics, says: “This strong focus on eco-efficiency and sustainability is present throughout the entire innovation cycle of the company. We ensure that key new product innovation and/or development follows these corporate principles.

Stanyl®
Stanyl HB grades (PA46) are used by several leading electronics OEMs in various applications for internal as well as external connectors. Roelof Westerbeek, Business Unit Director Asia for DSM Engineering Plastics says: “We believe that there is still a tremendous potential for further usage. Additionally, these materials are inherently lighter and tougher than materials that contain flame retardants and are also the best amongst other high temperature plastics. From our discussions across the supply chain we know that a UL94 HB material is more than sufficient for many applications.”

If still V2 or V0 is required, DSM Engineering Plastics has launched entirely halogen-free grades of Stanyl, a high performance polyamide that fulfills the highest flammability requirements such as UL94 V-0 and obtained approval at multiple customers.

Mr. Westerbeek: “The industry is starting to look into green design options that meet norms such as IEC62368 which will be in place by the end of 2008 and lays down clear guidelines for materials to be used for Audio, Video, and IT equipment.

Arnitel® TPE
Replacing PVC in cables and wires by a halogen free alternative has long been an objective in the electronics industry. Yet until recently, a broad deployment of such alternatives has been missing. Mr. Westerbeek: “Over recent years, demand from all major OEMs and their parts suppliers in the electronics industry for halogen free wire insulation materials has increased steadily. We introduced Arnitel XG with very positive results. This grade offers our customers a solution which is halogen free and meets all the industry standards in safety and electrical insulation.”

Other electrical systems such as white goods and power distribution switchgears are already progressively demanding materials that are halogen free and flame retardant. Roelof Westerbeek says: “The precautionary focus of our customers is valid. The extension to applications where product life-cycles are very long has already started happening, albeit at a less aggressive pace. Environmental standards eventually will make the whole electronics and electrical industry move to materials that are halogen free.”

Arnite® XG
White goods connectors, which are used in washing machines, dryers and dishwashers, are a typical area where this need has been voiced. The new IEC 60335-1 standard that specifies the requirements for unattended household appliances operating under high currents (>0.2A), is more difficult to meet. The requirements include a GWFI at 850°C (IEC 60695-2-12) and a glow wire test at 750°C on end products (IEC 60695-2-11 GWT). The GWT of 750°C has an extinguishing time of less then 2 seconds on assembled parts. 

Halogen-free Arnite XG is revolutionary because it is the first unfilled PBT which has tested positively according to GWT on end products. Arnite XG has a UL94 V-2 rating and matches the requirements for these applications. Arnite XG uses a flame retardant system that is free of halogen.

Akulon®
Power distribution switchgear such as Miniature Circuit Breakers and Molded Case Circuit Breakers too are following similar trends to go halogen-free. DSM’s Akulon polyamide 6 has been the traditional choice of all global and local low voltage switch gear manufacturers. Akulon was introduced in halogen free flame retardant grades for this segment more than 5 years ago.

This portfolio is now relatively large and the grades are UL registered in different glass and mineral combinations for various applications where halogen free solutions are needed.

Xantar®
Flame retardant Xantar polycarbonate and Xantar C PC/ABS grades meet UL94 V-0 and GWFI 960°C requirements without using any halogenated flame retardants.

Recent developments did result in a new Xantar family of special modified grades. Xantar XRM combines impact modification and improved stress crack resistance with flame retardancy. Based on the special nature of the modifier, no additional flame retardants are needed to achieve UL94 V-0 classification.

Jos Goessens says: “The innovative Xantar XRM product family outperforms standard polycarbonate grades in many aspects, while at the same time providing a real solution for customers who need to comply with the stringent environmental legislations.”

Flame-retardants
Flame-retardants are needed in certain plastics to meet stringent fire safety specifications in the electronics industry. Certain halogenated compounds (a subset of which are brominated flame retardants, or BFRs) are commonly used as flame retardants. Polyvinyl chloride (PVC) is used for many cables and wires with Chlorine acting as an efficient flame retardant.

BFRs and PVC are non critical in daily use by the end customer and show very effective FR-activity and have the best performance/safety balance. However, if inappropriate incinerated at the end of the life cycle of electronics equipment, specifically at temperatures below 800°C, there is a growing perception that these materials may have risks to health or the environment.

In line with the precautionary principles, a growing number of Original Equipment Manufacturers (OEMs) has announced to avoid the use of BFRs and PVC by switching to plastics which use non halogens as flame retardants and by using green design strategies (e.g. following the IEC62368 norm) that avoid the need of flame retarded plastics at all.