A macrocellular foam is described having improved cell size and
Fire-test-response Characteristics, among other features, which is
obtained by selecting a particle size less than 1 micron for the flame
retardant adjuvant. The inventors found that the amount of fire retardant
adjuvant can be increased for a given foam cell size or the foam cell
size can be increased for a given amount of fire retardant adjuvant,
allowing the production of foams having exceptionally large, well-formed,
cells that have excellent Fire-test-response Characteristics. The
benefits are especially noteworthy in relation to thermoplastic foams and
inorganic flame retardation adjuvants, due to the unexpected reduction in
the nucleation effect of the adjuvant. The foams are useful for improving
the acoustic performance of products that are required to meet certain
Fire-test-response Characteristics. It may be used in automotive and
other transportation devices, building and construction, household and
garden appliances, power tool and appliance and electrical supply
housing, connectors, and aircraft as acoustic systems for sound
absorption and insulation.