Surface functionalization of zirconium phosphate via sol-gel chemistry for optimizing fire safety and mechanical property of epoxy/intumescent flame retardant composites

Even though the incorporation of zirconium phosphate (ZrP) nanosheets can enhance fire safety of epoxy (EP) resin, the sole addition of ZrP nanosheets cannot make EP resin pass the UL94 V0 rating and obtain high limit oxygen index (LOI). Meanwhile, traditional intumescent flame retardants (IFR) also deteriorate the mechanical properties of EP/ZrP composites. Herein, for optimizing fire safety and mechanical property, organically modified ZrP (OZrP) nanosheets are prepared based on simple sol-gel chemistry and further combined with IFR to enhance the overall performance of EP composite. Compared to LOI values of pure EP (25) and EP/IFR composite (38), incorporating 2.0 wt% OZrP nanosheets further increase LOI to 44. Meanwhile, EP/IFR/2.0 wt% OZrP composite successfully pass the UL94 V0 rating at the thickness of 0.8, 1.6, and 3.2 mm. As expected, the deterioration of mechanical performance of epoxy resin caused by the addition of IFR is obviously suppressed by introducing OZrP nanosheets, confirmed by impact strength of up to 12.7 kJ/m² of EP/IFR/3.0 wt% OZrP composite. In the cone calorimeter test, the combination of 2.0 wt% OZrP and 20.0 wt% IFR significantly decreases the peak value of heat release rate and total heat release of EP resin by 83.9 % and 59.7 %. According to the microstructure and chemical composition of char residue, an intumescent and graphitized char formation mechanism is raised for the significantly enhanced fire safety in EP/OZrP/IFR composites. The optimization effect of OZrP nanosheets in the fire safety and mechanical property of epoxy/intumescent flame retardant composites further promote the practical application of epoxy resin.