Lightweight, Elastomeric, and Flame‐Retardant Foams from Expanded Chlorinated Polymers

Abstract Intrinsically flame‐retardant polymers based on lightweight and elastomeric microcellular foams are successfully prepared from flexible chlorinated polyethylene (CPE)/chlorinated polyvinylchloride (CPVC) compounds through compression molding foaming technology. The incorporation of CPVC to CPE at once improves the foam characteristics, and enhances the mechanical and fire performances. Due to the plausible intermolecular and intramolecular crosslinking among the polymer chains, the dense network structure of CPE/CPVC with enhanced strength results in increased cell size, reduced cell density, and improved dimensional stability of CPE/CPVC foams (CCFs). These improvements are noticed to be enhanced with increasing CPVC content in the CCF. Also, the flame‐retardant properties of the foams (i.e., limiting oxygen index and cone calorimeter combustion) are found to be increased with the increase of CPVC content. For instance, a highly flame‐retardant CCF at CPE/CPVC ratio of 60/40 shows a shorter combustion period, as derived from the respective heat release rate vs time curve. Corresponding peaks of heat release rate, total heat release rate, peak of mass loss rate, total smoke release, and char residue are recorded to be 8.4%, 5.8%, 3.0%, 6.6%, and 1000.1% of those recorded for the pristine CPE foam.