Highly Efficient Phosphazene-Derivative-Based Flame Retardant with Comprehensive and Enhanced Fire Safety and Mechanical Performance for Polycarbonate

Polycarbonate (PC) as a widely used engineering plastic that shows disadvantages of flammability and large smoke production during combustion. Although many flame-retardant PCs have been developed, most of them show enhanced flame retardancy but poor smoke suppression or worsened mechanical performance. In this work, a novel nitrogen–phosphorus–sulfur synergistic flame retardant (Pc-FR) was synthesized and incorporated into PC with polytetrafluoroethylene (PTFE). The extremely low content of PC-FR (0.1–0.5 wt%) contributes significantly to the flame retardancy, smoke suppression and mechanical performance of PC. PC/0.3 wt% Pc-FR/0.3 wt% PTFE (PC-P0.3) shows the UL-94 V-0 and LOI of 33.5%. The PHRR, THR, PSPR, PCO and TCO of PC-P0.3 decreased by 39.44%, 14.38%, 17.45%, 54.75% and 30.61%, respectively. The impact strength and storage modulus of PC-P0.1 increased by 7.7 kJ/m2 and 26 MPa, respectively. The pyrolysis mechanism of PC-P0.3 is also revealed. The pyrolysis mechanism of PC-P0.3 is stochastic nucleation and subsequent growth and satisfies the Aevrami–Erofeev equation. The reaction order of PC-P0.3 is 1/2. The activation energy of PC-P0.3 is larger than PC-0, which proves that the Pc-FR can suppress the pyrolysis of the PC. This work offers a direction on how to design high-performance PC.