Making polycarbonate flame retardant: Flame retardant selection and calorimetric analyses

Polycarbonate (PC) has been widely applied in aerospace and railway industries, and it is imperative to improve its fire safety related properties, especially heat release properties. Particularly, the MARHE value (maximum average rate of heat emission) directly obtained from the cone calorimeter (CONE) test is a comprehensive property that is presented in the EN45545-2 standard developed by the EU. In order to study the effect of flame retardants on the MARHE of polycarbonate, four flame retardants with different flame retardant mechanisms were used to prepare low heat release PC. CONE was used to characterize the heat release performance of PC, focusing on exploring the factors affecting MARHE and the method of preparing low heat release materials. The flame-retardant mechanism of PC was studied by SEM and TG/DTG. Meanwhile, the flame retardant index (FRI) is calculated as a reference for the flame retardant performance of PC. Results show the MARHE of HPCTP/PC is reduced by 31.12%, and it is confirmed that MARHE is influenced by time to ignition (TTI), peak heat release rate (PHRR), total heat release rate (THR), and the shape of the peak. Mica-RDP/PC materials were prepared based on the conclusions of MARHE derivation. RDP and Mica play a typical synergistic flame-retardant mechanism, with MARHE reductions from 20.31% to 20.00% of the single-component systems to 31.39%. All FRI values of PC materials are in the range of Good flame retardancy. This study provides a feasible way for the deep understanding and wide application of MARHE and the improvement of the fire safety performance of PC.