Fire Safety of Polymer Nanocomposites: An In-Depth Analysis Based on Functional Mechanisms

Polymeric materials face serious fire-safety challenges in construction, electrical and electronic devices, and aerospace because of their high heat release, melt-dripping tendency, and severe smoke and toxic emissions during burning. This review systematically summarizes the roles of nanofillers in the fire safety of polymer nanocomposites across three interconnected levels: functional mechanisms, regulatory factors, and macroscopic fire behavior. It focuses on four main mechanisms, namely physical barriers, catalytic charring, free-radical scavenging, and rheological network reconstruction, and further discusses how filler geometry, loading level, interfacial compatibility, dispersion state, and spatial orientation regulate fire-safety performance. By linking these factors to time to ignition, thermal stability, heat release, flame spread, and smoke emission and toxicity, the review clarifies the intrinsic structure–mechanism–property relationships. Current studies indicate that the fire-safety improvements provided by nanofillers do not arise from any single effect, but from their coupled regulation of heat transfer, mass transfer, radical reactions, and high-temperature rheology throughout thermal degradation, ignition, heat release, flame spread, and smoke and toxic-gas emission. Remaining challenges include the lack of unified evaluation criteria, limited in situ mechanistic evidence, and insufficient application-oriented rational design. Future work should establish verifiable, comparable, and predictive structure–mechanism–property relationships for polymer nanocomposites.