IMPAXXTM is the first commercial XPS foam product containing PolyFR in Europe. It is produced at the Dow STYROFOAMTM plants in Lavrion, Greece and Drusenheim, France. Coastal Automotive will use the new IMPAXX™ material to produce pre-cut and custom molded parts for specific automotive applications. Dow’s IMPAXX™ is designed for the automotive industry, and is used in applications such as overhead systems, doors and pillar trims to help absorb energy during impact.
Dow introduced the new PolyFR technology in 2011. It is a stable, high molecular weight, non-PBT (persistent, bioaccumulative, toxic) substance. This more sustainable additive enables XPS and expanded polystyrene (EPS) foams to continue to meet the increasing demands of international sustainability regulations. Coastal Automotive has been working together with Dow Automotive Systems and Dow Building Solutions on improving product quality and performance. The new IMPAXX™ material containing PolyFR represents a great leap forward in the environmental profile of the product.
The new Polymeric FR technology has received a number of high-profile business innovation awards including the 2012 R&D 100 Award, the 4th Annual Michigan Green Chemistry Governor’s Award, and the 2012 Wall Street Journal Technology Innovation Runners-up Award in the ‘Materials and Other Base Technologies’ category.
Dow has made the PolyFR technology available to the global extruded polystyrene (XPS) and expanded polystyrene (EPS) foam insulation industry through three manufacturing and marketing licensees. The international licensees, Chemtura (Emerald Innovation™ 3000), ICL (FR-122P) and Albemarle (GreenCrest™), have built commercial production capacity for the new polymeric flame retardant amounting to more than 14,000 MT at the end of 2013 which will be expanded to more than 25,000 MT by the end of 2014.
Dow Building Solutions will convert all of its STYROFOAM™ XPS foam plants in North America, Europe, Middle East, and Japan to the new Polymeric FR technology. Because of the vast number of plants, this is a phased process that started in Japan in 2013 and is followed by the conversion of plants in Europe and North America. This allows for a controlled conversion process that meets our quality requirements in every region and at the same time ensures product availability meeting global regulatory demands. All STYROFOAMTM plants in Japan were converted by the end of 2013.
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