Low flame retardant efficiency and poor acid resistance of filled polymer composites are two main drawbacks of magnesium hydroxide (MH) as a flame retardant (FR). To solve these problems, expandable graphite (EG) and microencapsulated red phosphorus (MRP) were introduced into polypropylene/ magnesium hydroxide (PP/MH) composite by melt compounding. The obtained PP/MH/EG/MRP quadruple composite was studied regarding its fire behavior as well as acid resistance. Obvious flame retardant synergism among MH, EG, and MRP is found in PP, which diminishes the loading of FR from 63.0 to 37.5 wt% to obtain V-0 rating in UL-94 test and low smoke release.Compact intumescent char with high thermo-oxidative stability was generated on composite surface, which plays a vital role in flame retardancy. The removal of MH by acid erosion on PP/MH/EG/MRP composite surface does not affect production of intumescent char and fire behavior of this composite.
Polypropylene (PP) was modified by expandable graphite (EG) and magnesium hydroxide (MH) to enhance its flame retardancy. The impact of EG particle size on fire behavior of PP/MH/EG ternary composite was studied in detail. The results reveal that EG synergizes markedly with MH in flame‐retarding PP. The PP/MH/EG composite with larger EG particle size displays better flame retardancy, smoke inhibition, acid resistivity, processability, and less toxic gas release upon combustion. The striking contrast derives from differences of charring behavior in condensed phase. The composite with larger EG particle size can produce intumescent char with larger expansion volume and better compactness and continuity, which hinders heat transfer inside polymer composite. Owing to much smaller expansion volume, the composite containing smaller EG particle size cannot generate effective fireproof barrier. As a consequence, this composite exhibits worse fire retardance and smoke inhibition in contrast with the composite with larger EG particle size.
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