ABSTRACTA novel flame retardant aluminum 2,4,6,8‐tetramethyl‐2,4,6,8‐teravinylcyclotetrasiloxane‐hypophosphorous acid (MVC‐AlPi) constituted based on hypophosphite and cyclotetrasiloxane groups was synthesized and characterized through fourier transform infrared and solid‐state nuclear magnetic resonance. The synergistic flame‐retardant behavior and mechanism of MVC‐AlPi/triphenyl phosphate (TPP) in polycarbonate (PC) were investigated. 5%MVC‐AlPi/5%TPP/PC composite got a highest limited oxygen index (LOI) value of 28.4% and passed UL94 V‐0 rating. The cone calorimeter test displayed that 5%MVC‐AlPi/5%TPP system not only inhibited the maximum combustion strength of PC composites, but also suppressed the total combustion reactions, which indicates a good synergistic flame‐retardant effect for MVC‐AlPi/TPP system. The photos of the residues disclosed that the pyrolysis solid fragments by MVC‐AlPi enhanced the residues mechanical strength, and the flexible film from TPP jointly restrained the release of fuels, thereby forming a synergistic barrier effect. The results from X‐ray photoelectron spectroscopy, Raman spectroscopy, and pyrolysis–gas chromatography–mass spectrometry showed TPP mainly exerted quenching effect in gas phase and MVC‐AlPi mostly promoted a charring effect in condensed phase. In addition, the thermal decomposition of MVC‐AlPi also produced some phosphoric acid derivatives which tended to capture benzene ring debris generated by combustion from TPP and to promote the formation of more high‐quality carbon barrier. At the same time, the anti‐impact and tensile strength results from electronic universal testing machine and electronic Izod impact testing machine showed that although the mechanical properties of composites were slightly deteriorated by the addition of MVC‐AlPi/TPP system into PC, the side effect for mechanical properties was still within acceptable limits. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020, 137, 48699.