Mineral fillers in intumescent fire retardant formulations - Criteria for the choice of a natural clay filler for the ammonium polyphosphate/pentaerythritol/polypropylene system

Addition of natural clay materials in intumescent polypropylene-based formulations (additive: ammonium polyphosphate and pentaerythritol) leads either to a decrease or to an increase of their fire retardant performances versus the chemical or the physical characteristics of the clay materials. A study of the factors affecting these performances has been carried out using linear and principal components analysis. This analysis shows that the results of the evaluation tests (LOI and UL 94) are affected in different ways by the adduct of the different clay material and that an increase in the LOI is not necessarily related to an increase in the UL 94 classification. LOI values are improved by the presence of the montmorillonite and of illite clay minerals which may react with acidic phosphate to form active carbonization catelysts, in addition, the results of the LOI test are improved by the presence of quartz and other foreign minerals in the clay materials. This study discusses the part played by the different constitutive minerals in the formation of defects in the polymer chain during the mixing process. It is proposed that the presence of these defects leads to a change in fire retardant performance.