Advancing flame retardancy, mechanical properties, and hydrophobicity of epoxy resins through bio-based cinnamaldehyde derivative

Developing flame retardants based on biomass materials to improve the flame retardancy and multifunctionality of epoxy resin (EP) is crucial. Herein, we synthesized a novel derivative, PPABCA, combining cinnamaldehyde and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide to serve as flame retardants for EP. Incorporating 5 wt% PPABCA into EP (EP/PPABCA-5) demonstrated remarkable flame retardancy, with a limiting oxygen index of 33.7% and a V-0 rating in UL-94 test. It also reduced the peak heat release rate, total heat release, and peak CO₂ production by 32.9%, 29.9%, and 42.8%, respectively. The enhanced flame retardancy was facilitated by the capture of phosphorus-containing free radicals coupled with dilution of combustible gas characterized by the blow-out phenomenon and formation of a dense char layer enriched with triazine and phosphorus. Furthermore, EP/PPABCA-5 exhibited enhanced flexural and tensile strengths by 20.5% and 16.5% compared to EP, attributed to the increased cross-linking density and π-π conjugation from the high rigidity of PPABCA, along with its good compatibility with EP. Additionally, the improved hydrophobic properties of PPABCA, confirmed by electrostatic potential analysis, further enhanced the hydrophobicity of EP composites. Overall, this work underscored a strategic development of multifunctional, bio-based flame retardant, showcasing efficient flame retardancy, enhanced mechanical properties, and boosted hydrophobicity in EP.