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<p>This work studies the development of multifunctional epoxy coatings that are enhanced with zinc borate and micro-encapsulated boric acid to simultaneously improve their anticorrosive and flame-retardant properties. Microcapsules were developed by encapsulating different concentrations of boric acid and zinc borate in a urea–melamine–formaldehyde (UMF) shell and then incorporating them into an epoxy matrix. The encapsulation allowed for a controlled release mechanism that activated in response to mechanical damage or environmental stimuli. Among the five formulations evaluated, Batch 4 (1.5&#xa0;g boric acid and 0.5&#xa0;g zinc borate) performed the best overall. Flame retardancy testing revealed higher UL-94 ratings and limiting oxygen index (LOI) values, with Batch 4 earning a V-0 rating and LOI of 28.5%, compared to V-2 and 23.0% for the plain epoxy. In corrosion testing, Batch 4 showed the best protection, delaying rust formation for more than 500&#xa0;h in a 3.5-wt% NaCl environment. The UMF microcapsules enabled controlled release of active compounds in response to thermal or mechanical stimuli, ensuring long-term protection. These findings focus on the combined functional benefits of boric acid and zinc borate microcapsules in epoxy coatings, making them strong candidates for advanced protective applications.</p> Graphical abstract <p></p>

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Enhancing flame-retardant properties of epoxy resin using micro-encapsulated boric acid and zinc borate in a urea–melamine–formaldehyde shell.

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Akash R. Parvate,
  • Akshay R. Wasnik,
  • Himanshu A. Patil,
  • Gufran Ansari,
  • Aarti P. More

摘要

This work studies the development of multifunctional epoxy coatings that are enhanced with zinc borate and micro-encapsulated boric acid to simultaneously improve their anticorrosive and flame-retardant properties. Microcapsules were developed by encapsulating different concentrations of boric acid and zinc borate in a urea–melamine–formaldehyde (UMF) shell and then incorporating them into an epoxy matrix. The encapsulation allowed for a controlled release mechanism that activated in response to mechanical damage or environmental stimuli. Among the five formulations evaluated, Batch 4 (1.5 g boric acid and 0.5 g zinc borate) performed the best overall. Flame retardancy testing revealed higher UL-94 ratings and limiting oxygen index (LOI) values, with Batch 4 earning a V-0 rating and LOI of 28.5%, compared to V-2 and 23.0% for the plain epoxy. In corrosion testing, Batch 4 showed the best protection, delaying rust formation for more than 500 h in a 3.5-wt% NaCl environment. The UMF microcapsules enabled controlled release of active compounds in response to thermal or mechanical stimuli, ensuring long-term protection. These findings focus on the combined functional benefits of boric acid and zinc borate microcapsules in epoxy coatings, making them strong candidates for advanced protective applications.

Graphical abstract