Summary: This paper reviews recent approaches for making intumescent systems. The mechanisms of action involving intumescence are described and commented on. Synergistic aspects using zeolites and organoclays are also considered and discussed. New strategies are examined on the basis of the mechanism of intumescence. The approach of using char forming polymers as additives (blend technology) is also fully discussed. This consists of substituting classical polyols (char forming agents) with char forming polymers (polyamides and thermoplastic polyurethane). It will be shown that the advantages of this concept are to obtain flame‐retarded (FR) polymer blends with improved mechanical properties in comparison with polymers loaded with classical formulations, and the avoidance of problems due to the water solubility of the polyols and their migration. The “nanocomposite approach” enhances the performance of intumescent systems by using a nanostructured char forming polymer. It will be shown that this combination of intumescence via the blending approach and nanocomposites enhances both flame retardancy and mechanical properties, and allows many specifications to be produced (for example, the design of EVA‐based materials for flame retarded low voltage cables and wire). This appears to be one of the most promising ways for designing new efficient intumescent materials.Intumescent residue after LOI test of an intumescent poly(propylene).magnified imageIntumescent residue after LOI test of an intumescent poly(propylene).

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