In this article, thermoplastic polyurethane-microencapsulated ammonium polyphosphate (MTAPP) is prepared and well characterized by Fourier transform infrared spectroscopy, scanning electron microscopy, and thermogravimetric analysis (TGA). MTAPP and APP are added onto polypropylene (PP) as a novel intumescent flame-retardant system to improve the flame retardancy of PP. The flammability, thermal stability, and mechanical properties of the flame-retardant PP composites are investigated by limiting oxygen index (LOI), UL-94 vertical burning test, cone calorimeter test (CCT), TGA, and mechanical properties tests. The results show that MTAPP exhibits better flame retardancy and thermal stability than that of the APP in the flame-retardant PP composites. The LOI value of the PP/MTAPP composite at the same loading level is higher than that of PP/APP composite. The dripping of MTAPP system disappears compared with APP system from UL-94 test. The results of the CCT also indicate that MTAPP is an effective flame retardant in PP. The improvement may be attributed to the better charring capacity of MTAPP from TGA. Additionally, the mechanical properties of MTAPP are better than those of APP in PP.
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