Improved Fire Resistance of Nylon‐6 via Graphitic Carbon Nitride‐Mediated Intumescent Char Formation

Addressing the critical need of sustainable, highly efficient, halogen‐free flame‐retardant system, this work introduces a synergistic strategy to overcome the “loading paradox” in Nylon‐6 (Ny) by integrating graphitic carbon nitride (gCN) and melamine cyanurate (MC). The optimum composition (Ny/MC/gCN3) was obtained at 3 phr of gCN and 13 phr of MC, mixed with 100 parts of Nylon‐6. The composite (Ny/MC/gCN3) exhibited superior flame retardancy with 32% LOI and passed V0 rating in UL‐94 test with anti‐dripping property. Incorporation of the synergist reduced the PHRR by 49%, THR by 46.8%, and smoke optical density by 46.6% in the composite along with enhancing the mechanical properties. The novelty of the study lies in processing, improved LOI, ~3.5 times enhanced smoke density and also in the selection of polymer (highly flammable industrial Nylon‐6) when compared to existing literature with the same synergistic system (with bio‐based Nylon 56).