Flame-retarded bisphenol A polycarbonate/silicon rubber/bisphenol A bis(diphenyl phosphate): Adding inorganic additives

Various inorganic additives belonging to four different groups: layered materials, metal hydroxides, metal oxides/carbonate and metal borates are investigated in bisphenol A polycarbonate/silicon rubber/bisphenol A bis(diphenyl phosphate) (PC/SiR/BDP) to improve flame retardancy. The pyrolysis, reaction to small flame and fire behaviour of the blends are characterised and structure property relationships discussed. Among the added layered materials, talc functions as an inert filler with potential for commercialisation, whereas organically modified montmorillonite (LS) enhances decomposition. PC/SiR/BDP + talc and PC/SiR/BDP + LS reinforce the char and induce a flow limit. The different dispersion and location of boehmite (AlO(OH)) nano-particles and Mg(OH)(2) micro-particles determine the impact on performance. PC/SiR/BDP + Mg(OH)(2) shows additional hydrolysis and thus reduced flame retardancy. AlO(OH) is embedded in SiR and thus behaves as an inert filler. Both additives worked as smoke suppressants. Using selective filling with nano-particles is proposed as an interesting route for flame retardancy in PC/SiR blends. Adding metal oxides and carbonate (MgO, CaCO3 and SiO2) changes the decomposition pathways of PC/SiR/BDP, worsening the fire performance of PC/SiR/BDP. CaCO3 harbours the potential to intumescence, even though an early collapse of the char structure occurred. Adding hydrated metal borates, CaB, MgB and ZnB, changes the pyrolysis and flame retardancy action. Smoke suppression occurs; LOI is improved as well as UL 94 classification. ZnB performs better than MgB and CaB. The comprehensive study, also based on systematic material variation, delivers valuable guidelines for future development of flame-retarded multi-component PC blends. (C) 2013 Elsevier Ltd. All rights reserved.