The effect of expandable graphite (EG) and modified halloysite nanotubes (HNTs) on the flame retardant properties of silicone rubber foam (SiF) was studied in this paper. Modified HNTs were obtained by surface modification of the silane-coupling agent A-171. The flame retardancy of SiF was studied by limiting oxygen index (LOI), vertical combustion and cone calorimeter tests. The mechanical properties of SiF were analyzed by a universal mechanical testing machine. The LOI results showed that EG/HNTS@A-171 could enhance the LOI of SiF. The cone calorimeter test results showed that EG/HNTS@A-171 effectively reduced the peak heat release rate, the total heat release rate, the smoke production rate, the total smoke production rate, the CO production rate and the CO₂ production rate and increased the carbon residue rate. TGA shows that main chain pyrolysis temperature of the SiF is delayed by 123 °C. The mechanical properties test results showed that EG/HNTS@A-171 improved the tensile strength of SiF. These results indicated that EG/HNTS@A-171 can significantly improve the flame retardant performance of SiF.

The flame-retardant micro-encapsulated sepiolite (MSEP) was successfully prepared by sol-gel method. Fourier transform infrared, X-ray photoelectron spectroscopy, scanning electron microscopy, and energy dispersive spectroscopy were utilized to prove that sepiolite was encapsulated. Then, the mechanical properties, flame retardance, smoke suppression, and pyrolysis characteristics of silicone rubber foam (SiFs) with MSEP and zinc borate (ZB) were analyzed. The results indicated that the tensile and compressive properties of SiFs could evidently improve with the incorporation of MSEP/ZB. SiFs with 3 wt% MSEP and 6 wt% ZB could achieve an limiting oxygen index value of 30.9 vol% and UL-94 V-0 rating, the time to ignition was 64.7% above that of pure SiFs, the peak heat release rate and total heat release were 42.7% and 25.0% lower than that of pure SiFs, respectively. Furthermore, the peak smoke production rate and total smoke production of SiFs with 3 wt% MSEP and 6 wt% ZB were merely 54.22% and 64.10% of pure SiFs. Especially, the thermal stability of SiFs was significantly enhanced, and the carbon residue of SiFs became denser and more complete after adding 3 wt% MSEP and 6 wt% ZB.

Silicone rubber foam (SiF) with EG/HPCTP was prepared by high-temperature vulcanization. The flame retardancy of SiF was evaluated using the LOI (limiting oxygen index), UL-94, cone calorimetry test (CCT), thermogravimetric analysis (TGA), and mechanical properties. The results showed that EG/HPCTP could improve the LOI of SiF, and the SiF could pass the UL-94 V-0 rating. Compared with pristine SiF, EG/HPCTP could reduce the total heat release rate (THR), heat release rate (PHRR). Digital images of the char residues showed that the HPCTP was beneficial to promote the strength of SiF with EG. TGA showed that the branched decomposition temperature and main chain pyrolysis temperature of SiF were delayed. Mechanical properties analysis showed that EG and HPCTP could improve the mechanical properties of SiF. These indicated that the addition of EG/HPCTP was a good approach to prepare high effective flame-retarding SiF.