Thermoplastic materials are naturally prone to burning because, like most hydrocarbon-based substances, they readily ignite once exposed to sufficient heat. During combustion, heat breaks down their long molecular chains into volatile hydrocarbons along with hydrogen and hydroxyl radicals. These high-energy byproducts react rapidly with oxygen, generating more heat and allowing flames to propagate.
To counter this, flame retardant additives are incorporated into polymers such as polyolefins, polycarbonate, polyamide, and polyester. Their function is to reduce ignition risk, slow flame propagation, suppress smoke formation, and minimize dripping. The primary purpose is to delay burning long enough to protect people in the event of a fire, with the added benefit of reducing property damage.
Flame-retardant plastics are widely used in everyday environments—homes, offices, vehicles, public transportation, electronics, and industrial equipment. Many markets and products require them under strict building codes and industry standards. Examples include construction fabrics, insulation materials, banners, roofing, automotive interiors, aircraft components, seating, mattress covers, electronic housings, wiring, power cables, tunnels, and more.
A fire requires three elements: a fuel source, oxygen, and heat. Flame retardants interfere with one or more parts of this triangle, either physically or chemically.
Physical mechanisms include:
Cooling the substrate below its combustion temperature
Creating a barrier (solid or gaseous) to block oxygen
Releasing inert gases that dilute combustible vapors
Chemical mechanisms include:
Interrupting gas-phase free-radical reactions
Encouraging the formation of a carbon-rich char layer that insulates the polymer
Commercial flame retardants most commonly used today include halogenated compounds, phosphorus-based additives, and various metal oxides.
| Тип | Characteristics | Типичные области применения |
|---|---|---|
| Halogenated | Highly effective and cost-efficient; typically contain bromine or chlorine. | Automotive parts, electronics housings, PE films, etc. |
| Halogen-Free | Environmentally friendly; uses phosphorus, nitrogen, or metal hydroxides to avoid toxic smoke. | Public transport interiors, green building materials, consumer electronics, PET film, etc. |
| Carrier-Specific | Formulated for specific resins like Polyethylene (PE), Polypropylene (PP), Polyamide (Nylon), or Polycarbonate (PC), Polyethylene Terephthalate(PET). | Electrical conduits, wiring harnesses, lithium battery housings. |
Organic halogen compounds—particularly brominated types—are the most widely used plastics flame retardants. They work by neutralizing high-energy radicals involved in combustion, significantly reducing the fuel gases released.
Brominated flame retardants offer excellent cost-to-performance value. They usually require lower loading levels than metal hydroxides such as ATH or magnesium hydroxide and maintain good mechanical integrity in the polymer. Their easy processability makes them especially suitable for polyethylene and polypropylene films.
Chlorinated flame retardants are also common and typically supplied as chlorinated paraffins or cycloaliphatic structures. Although less expensive than brominated types and more resistant to light degradation, they are less thermally stable and may be more corrosive during processing. Cycloaliphatic chlorinated additives withstand higher temperatures—up to about 320°C—than paraffin grades.
Both brominated and chlorinated flame retardants require synergists, such as antimony trioxide, zinc borate, or zinc molybdate. Synergists work by forming compounds (e.g., antimony trihalides) that improve radical suppression, boosting the effectiveness of the halogenated flame retardant.
While some brominated compounds have faced scrutiny, European Union reviews—including studies referenced in 2005—have found commercial decabromodiphenyl ether (decabrom) safe for human health and exempted it from RoHS restrictions.
Non-halogenated flame retardants fall into two categories: phosphorus-based char formers и metal oxide endothermic additives.
Organic and inorganic phosphorus compounds work in multiple ways:
Neutralizing combustion radicals in the vapor phase
Releasing phosphoric acid under heat, which alters polymer decomposition
Promoting char formation to block oxygen and heat access
Although highly effective, phosphorus additives may degrade at extrusion temperatures above 400°F (≈204°C), potentially affecting polymer properties or damaging processing equipment.
Aluminum trihydrate (ATH) and magnesium hydroxide are the most common halogen-free options.
ATH decomposes at 180–200°C, absorbing heat and forming aluminum oxide. It is inexpensive and naturally abundant but limited to lower processing temperatures.
Magnesium hydroxide decomposes at ~300°C and meets strict regulatory requirements. However, both materials require high loadings—sometimes up to 65%—which can negatively affect mechanical strength and processability.
Other flame-retardant chemistries include boron compounds, melamine, ammonium sulfamate, and emerging technologies such as nanoclays and silicon-based additives that aim to deliver flame protection with lower addition levels.
Flame-retardant masterbatches are typically engineered to match the rheology and molecular characteristics of the base polymer. The recommended dosage depends on the flame-resistance rating required.
For polyolefins:
10–14% masterbatch addition typically meets UL 94 V-2
18–20% is usually needed for UL 94 V-0
Achieving a V-0 rating is easier with a polymer of high molecular weight and low melt flow index. Because polyolefins tend to drip when burning, incorporating fillers such as clay can help minimize dripping—though this may reduce the efficiency of halogenated flame retardants.
Choosing the correct flame-retardant system requires answering several key questions:
Which type is permitted—halogenated or non-halogenated?
Which standards apply? UL 94, E 84, MVSS, ASTM, VW-1, etc.
What classification is needed? V-2, V-1, or V-0 for UL-94
Are mechanical properties critical? (e.g., tensile strength, elongation)
Is blooming a risk for processes like sealing or printing?
Is UV resistance important? Will the product be exposed to sunlight?
If you need огнестойкий мастербатч for your application, please contact flame retardant masterbatch supplier to give you flame retardant solution.
Evaluates flammability and dripping for polymers used in electronics and appliances. Samples are burned twice for 10 seconds each, with flame duration and dripping effects recorded.
Ratings include:
V-0: ≤10 seconds after-flame; no dripping that ignites cotton
V-1: ≤30 seconds after-flame; no ignition of cotton
V-2: Same as V-1, but dripping that ignites cotton is allowed
Measures the minimum oxygen concentration needed to sustain combustion.
Used for evaluating materials in air-duct systems.
Assesses flame propagation in films and fabrics using small- and large-flame tests.
Determines flame spread and smoke development for building materials on exposed surfaces.
Requires interior automotive materials to burn at <4 inches/min for safety compliance.
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