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<p>To address the flammability, dense smoke emission, and fire safety concerns of epoxy resin (EP) in automotive components, this study develops a sulfur-free, multi-element reactive flame retardant (FA) integrating phosphorus, nitrogen, boron, and silicon. Synthesized from 4-formylphenylboronic acid, 3-aminopropyltriethoxysilane, and DOPO, FA enables a synergistic flame-retardant mechanism in EP. At a 2.5 wt% FA loading, the composite attained a UL-94&#xa0;V-0 rating and displayed a limiting oxygen index of 29.1%, with complete suppression of dripping. Based on cone calorimeter measurements, the modified epoxy resin EP/FA7.5 exhibited significant reductions: a 41.4% decrease in peak heat release rate, a 27.7% decline in total heat release, and a 36.5% drop in cumulative smoke production. Crucially, the EP/FA7.5 composites meet the stringent EN45545-2 HL 1 smoke density standards (D<sub>s</sub>(4) and VOF<sub>4</sub>) and exhibit superior smoke suppression. FA promotes a dense char layer in the condensed phase and enhances mechanical properties: EP/FA5 exhibits a flexural strength of 103.6&#xa0;MPa due to rigid aromatic interactions. This work presents a scalable strategy for fabricating fire-safe, high-performance epoxy composites demonstrating potential for application in fields requiring high fire safety, such as transportation and electronics.</p>

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Multifunctional P/N/B/Si synergistic system for high-efficiency flame-retardant and smoke-suppressive epoxy composites

  • 期刊论文

  • 发表日期：

    2025年11月7日

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  • Guoyong Lan,
  • Wanyu Huang,
  • Jun Wang,
  • Guimin Zhou,
  • Haopeng Cai

摘要

To address the flammability, dense smoke emission, and fire safety concerns of epoxy resin (EP) in automotive components, this study develops a sulfur-free, multi-element reactive flame retardant (FA) integrating phosphorus, nitrogen, boron, and silicon. Synthesized from 4-formylphenylboronic acid, 3-aminopropyltriethoxysilane, and DOPO, FA enables a synergistic flame-retardant mechanism in EP. At a 2.5 wt% FA loading, the composite attained a UL-94 V-0 rating and displayed a limiting oxygen index of 29.1%, with complete suppression of dripping. Based on cone calorimeter measurements, the modified epoxy resin EP/FA7.5 exhibited significant reductions: a 41.4% decrease in peak heat release rate, a 27.7% decline in total heat release, and a 36.5% drop in cumulative smoke production. Crucially, the EP/FA7.5 composites meet the stringent EN45545-2 HL 1 smoke density standards (Ds(4) and VOF4) and exhibit superior smoke suppression. FA promotes a dense char layer in the condensed phase and enhances mechanical properties: EP/FA5 exhibits a flexural strength of 103.6 MPa due to rigid aromatic interactions. This work presents a scalable strategy for fabricating fire-safe, high-performance epoxy composites demonstrating potential for application in fields requiring high fire safety, such as transportation and electronics.