Synergistic effects of organically modified montmorillonite in combination with metal oxides on the fire safety enhancement of intumescent flame-retarded epoxy resins

Synergistic effects of organically modified montmorillonite (OMMT) in combination with different metal oxides (Bi₂O₃, Sb₂O₃, and MoO₃) on the fire safety enhancement of the intumescent flame-retarded epoxy resins (EPs) were systematically evaluated. The results from X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses show that the OMMT and metal oxides acquire a uniform distribution in the EP matrix, and OMMT platelets exhibit a fully exfoliated state. The flammability and thermogravimetry (TG) tests show that the intumescent flame retardant (IFR)-OMMT-metal oxide ternary system can endow EPs with the higher synergistic efficiencies on the enhancement of flame retardancy, smoke suppression properties, and charring ability compared to those of IFR or IFR-OMMT system, and the synergistic efficiency is the following order: IFR/OMMT/Sb₂O₃ > IFR/OMMT/MoO₃ > IFR/OMMT/Bi₂O₃. In particular, the sample, filled with 1.5 wt% OMMT, 1.5 wt% Sb₂O₃, and 27 wt% IFR, passes the UL94 V-0 rating and acquires the highest limiting oxygen index value of 28.5% among the samples. The IFR-OMMT-metal oxide ternary system exerts a better synergistic effect on the generation of crosslinking and aromatic structures that supply the excellent charring effect and barrier effect for the EPs, and the synergistic efficiency of IFR-OMMT-metal oxide ternary system is varied with the types of metal oxides.