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Low-Flammability Hybrid Polymer Materials Based on Epoxy Oligomers and In Situ-Synthesized Zinc-Containing
Sergey Vladimirovich Borisov1, Boris Andreevich Buravov1, Daria Andreevna Kudryavtseva1
1Faculty of Chemical Technology, Volgograd Technical State University, 400005 Volgograd, Russia.
Polymers
|December 31, 2025
Summary
Developing in situ-formed hybrid epoxy composites with zinc sulfate and orthophosphoric acid significantly improved fire safety. This novel approach enhances char residue while reducing heat and smoke release in advanced materials.
Area of Science:
- Materials Science
- Polymer Chemistry
- Fire Safety Engineering
Background:
- Traditional dispersed fire retardants in epoxy composites suffer from anisotropy, reduced mechanical strength, and poor filler impregnability.
- Developing advanced fire-safe materials is crucial for enhancing structural integrity and safety in various applications.
- Epoxy resins, widely used in composites, require effective fire retardant strategies to mitigate flammability risks.
Purpose of the Study:
- To develop novel in situ-formed hybrid epoxy composites with enhanced fire resistance.
- To investigate the impact of in situ particle formation on the properties of epoxy composites.
- To overcome the limitations of conventional fire retardant systems in polymer matrices.
Main Methods:
- Modification of diglycidyl ether of bisphenol A and triethylenetetramine epoxy system with zinc sulfate heptahydrate in orthophosphoric acid.
- In situ formation of near-spherical microparticles (6-16 µm) within the polymer matrix.
- Characterization using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and Fourier-transform infrared spectroscopy (FTIR).
Main Results:
- Significant enhancement in fire resistance properties of the modified epoxy composites.
- Increased char residue by 1.7-2.2 fold compared to unmodified epoxy.
- Reduced total heat release (up to 60.5%), peak heat release rate (up to 40.2%), and smoke release (up to 70%).
Conclusions:
- The in situ formation strategy effectively creates fire-safe epoxy composites with improved properties.
- Accelerated thermal-oxidative degradation, indicated by increased mass loss rate, promotes enhanced char formation.
- This approach offers a promising method for developing high-performance, fire-safe epoxy materials for demanding applications.
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