Flame Retardant Polypropylene Basics
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August 27, 2025
Flame-retardant polypropylene materials can be categorized into five main types, each with unique characteristics and applications. One of the earliest and most commonly used systems is the halogen-antimony flame retardant system, which operates through a gas-phase mechanism. Common halogen-based flame retardants include decabromodiphenyl ether, hexabromocyclododecane, octabromoether, and tetrabromobisphenol A, often combined with antimony trioxide as a synergist. These materials are effective at low concentrations and provide good fire resistance. However, due to environmental concerns and the release of toxic fumes during combustion, their use has been restricted in many countries. Despite this, they are still permitted in regions like the United States and Japan. In China, as a developing country, these halogen-based flame retardants are expected to remain in use for at least the next decade.
Another approach involves brominated phosphate esters, such as bromoalkyl phosphates. These compounds not only enhance flame resistance but also improve the flow and processability of polypropylene. They have minimal impact on the mechanical properties of the material, making them a popular choice for various applications.
In recent years, intumescent flame retardants have gained significant attention. Pioneered by Professor Camino from the University of Turin, Italy, this type of flame retardant offers high efficiency, thermal and light stability, low toxicity, and reduced smoke and corrosion. It is also environmentally friendly and does not significantly affect processing or mechanical properties. Adding just 25–30 parts per hundred parts of polypropylene (phr) can achieve the UL94 V0 rating. Although domestic production of such products is still in its early stages, the technology is rapidly advancing.
Graft copolymer-based flame retardants, such as those using pentabromobenzyl acrylate and EPDM rubber, offer enhanced impact strength. These materials are suitable for engineering plastics and are particularly useful in applications requiring both durability and flame resistance.
Lastly, inorganic fillers like aluminum hydroxide (ATH) and magnesium hydroxide are widely used for their flame-retardant and smoke-suppressing properties. To achieve optimal performance, these fillers must be finely ground and surface-treated. Proper surfactant selection is crucial to ensure compatibility with the polymer matrix and uniform dispersion without compromising mechanical properties. Since ATH and magnesium hydroxide function effectively at different temperature ranges, combining them can provide continuous flame resistance over a broader temperature spectrum. When using magnesium hydroxide in polypropylene, it is recommended to adopt a two-step charging method during compounding to achieve better flame resistance and maintain favorable mechanical properties.