Novel Aryl Phosphate for Improving Fire Safety and Mechanical Properties of Epoxy Resins

Epoxy resins (EPs) are highly flammable, and traditional flame retardant modifications often lead to a significant reduction in their mechanical performance, limiting their applications in aerospace and electrical and electronic fields. In this study, a novel flame retardant, bis(4-(((diphenylphosphoryl)oxy)methyl)phenyl)phenyl phosphate (DMP), was successfully prepared and introduced into the EP matrix. When the addition of DMP was 9 wt%, the EP/9 wt% DMP thermosets passed the UL-94 V-0 rating, and their LOI was increased from 24.5% of EP to 35.0%. With the introduction of DMP, the phosphoric acid compounds from the decomposition of DMP promoted the dehydration and charring of the EP matrix, and the compact, dense char layer effectively exerted the shielding effect in the condensed phase. Meanwhile, the produced phosphorus-containing radicals played a quenching effect in the gas phase. As a result, the peak heat release rate (PHRR) and total heat release (THR) of EP/9 wt% DMP were reduced by 68.9% and 18.1% compared to pure EP. In addition, the polyaromatic structure of DMP had good compatibility with the EP matrix, and the tensile strength, flexural strength and impact strength of EP/9 wt% DMP were enhanced by 116.38%, 17.84% and 59.11% in comparison with that of pure EP. This study is valuable for expanding the application of flame-retardant EP/DMP thermosets in emerging fields.