Influence of incorporation methods of ATH on microstructure,elastomeric properties,flammability, and thermal decomposition of dynamically vulcanized NR/PP blends

Flame‐retardant thermoplastic vulcanizates (TPVs) of natural rubber (NR)/polypropylene (PP) (60/40 wt %) blends filled with alumina trihydrate (ATH) were prepared with an internal mixer. To increase the properties of flame‐retardant NR/PP TPV, the new mixing method, stepwise masterbatch mixing (SMB) method was adopted. The effects of SMB method along with different ATH loadings on microstructure and properties of NR/PP TPVs were investigated. Conventional one‐step mixing (CV) method was also studied for comparison. Transmission electron microscopy analysis showed that different processes led to a variation in microstructural homogeneity, which imposed various effects on blend properties. The mechanical properties of TPVs changed with ATH loading, and the strength of the samples obtained from SMB method was higher than those of CV method. LOI and cone calorimetry tests revealed that the flame retardancy of NR/PP blends dramatically increased at higher ATH loading. Furthermore, the increment level of flame retardancy was accelerated in the blends produced particularly through SMB method, resulting from homogeneity of local ATH distribution in NR/PP blend. Greater combustion resistance of blends prepared from SMB route were confirmed by thermogravimetry and pyrolysis‐gas chromatography–mass spectrometry techniques. Finally, a burning mechanism between filler structure and flammability of NR/PP TPVs obtained from CV and SMB methods was discussed. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46231.