Abstract
A multi-element synergistic flame retardant with double-bond structure was synthesized and added to epoxy resin (EP) to obtain EP composites with high flame retardant and mechanical properties. The study demonstrated that the DOPO-KhCPA-5 composite, containing 5 wt% of DOPO, exhibits the limiting oxygen index (LOI) value of 32%, indicating a high resistance to combustion. Additionally, it successfully meets the UL-94 V-0 grade, indicating excellent self-extinguishing properties. The DOPO-KhCPA-5 compound exhibited a 48.7% decrease in peak heat release rate (PHRR) and a 7.2% decrease in total heat release (THR) compared to pure EP. The inclusion of double-bonded architectures in the DOPO-KhCPA-5 composites led to a significant enhancement in both the tensile strength and tensile modulus. Specifically, the tensile strength increased by 38.5% and the tensile modulus by 57.9% compared to pure EP. This improvement can be attributed to the formation of a fully interpenetrating network of macromolecular chain structures by DOPO-KhCPA within the EP matrix. This network increased the entanglement between molecular chains, resulting in positive effects on the mechanical properties of the EP. Multi-element of DOPO-KhCPA exhibits a synergistic effect, providing condensed and noncombustible gas-phase flame retardancy. Additionally, the mechanical properties were improved with the introduction of flame retardants due to the good impact of double-bond cross-linking. The effectiveness of DOPO-KhCPA as an additive for developing high-performance EP with significant potential applications has been proven.