Fluoropolymer foams are high performance closed-cell foams based on polyvinylidene fluoride (PVDF) that bring new materials solutions to the life sciences and semi-conductor industries. Both industries require the use of ultra-high purity materials with low smoke generation and outstanding flame and chemical resistance. For many years, fluoropolymers, such as PVDF and its copolymers, have been successfully used for fluid handling and packaging systems. The introduction of new fluoropolymer foams fills a gap by adding flame retardant and chemically resistant insulation materials.

Molded fluoropolymer foams¹

LIFE SCIENCES
Today’s pharmaceutical industry uses the latest technologies to develop and manufacture medicines that dramatically improve the quality of life and increase life expectancy. The cost to develop, produce, pass FDA approvals and deliver these drugs to consumers can be as much as $800 million per new medicine. The financial impact is very large if production of these medicines is slowed or shut down due to fire or smoke damage. Even the slightest delay in production can result in significant losses.

New, sophisticated medicines are made using advanced manufacturing technologies and materials. High technology, “clean-room” environments often contain polymeric sheet and polymeric foam for insulation. These are used to create lightweight structures, partitions, chemical wet benches, and pipe and ducting insulation. These environments may also include wiring, flexible non-metallic conduit for fiber optic cables, as well as process control and automation wiring.

Foam sheet and tubes 1

SEMICONDUCTORS
The semiconductor manufacturing environments require the use of materials with excellent chemical resistance, purity, and low smoke generation in the event of a fire. PVDF polymers are commonly used because of their high purity and low smoke generation, and are widely used by the semiconductor industry to supply high-purity water to chip manufacturing operations. They are also used in the fabrication of wet benches. Since most chemicals do not alter PVDF, it has been adopted by the chemical process and pulp and paper industries for vessel lining and piping systems. PVDF is also characterized by its strength, toughness, and long-term resistance to both UV and gamma radiation.

In addition, PVDF is used to insulate data communications, fiber optic, fire alarm, and control cables because it will not easily propagate a fire and produces minimal smoke when burned. The excellent fire performance properties of PVDF allow for the installation of wire and cable products in building air-handling spaces without the need for metal conduits.

In order to limit the risk due to fire and smoke, Factory Mutual (FM), Underwriters Laboratories (UL), ASTM, and other testing agencies have developed fire-testing methods to characterize the fire performance of materials. It is generally recognized by these agencies that the best testing methods are full-scale tests or scaled-down versions that take into account where and how the product will be used. These test methods often use solid sheets, mounted horizontally or vertically, which are then exposed to a heat source and/or direct flame. These test methods are also used for testing polymeric foams, wire, and cable, and characterize performance by measuring flame spread and smoke generation as the polymer burns. In the case of wire and cable products, the cables are laid side by side in a closed chamber called a Steiner Tunnel (ASTM E84/NFPA 262/NFPA255) and fire performance is again characterized by flame spread and smoke generation. There are a number of nationally recognized testing laboratories that can performthese tests.

Many polymeric materials will readily burn and produce large amounts of smoke, as well as contribute significant fuel load, should a fire occur. However, fluoropolymers, especially PVDF, prevent and minimize fire hazards. PVDF is a pure polymer and is inherently flame retardant without additives. PVDF is characterized by:

• High auto-ignition temperature
• Low caloric value
• Self extinguishes when a direct flame is removed
• Minimal fire propagation and minimal smoke generation
• Resistance to most chemicals, including typical sterilization methods
• High purity
• UV and gamma radiation resistant
• Toughness and cut-through resistance