Abstract

Numerous previous investigations have exploited single-component aluminum hydroxide, silica, or phosphorus-containing organic agents to improve the fire resistance of epoxy resin. Existing literature confirms that ATH relies on endothermic dehydration and inorganic barrier layers to suppress combustion, while phosphorus organics exert radical quenching effects in the gas phase. However, separate use of these fillers generally requires high loading to achieve satisfactory flame retardancy, which inevitably weakens the mechanical properties of the epoxy matrix; few studies integrate N, P, and Si elements into ATH via chemical grafting to realize synergistic flame retardancy at low filler dosage, and the dual heat-transfer regulation effect of formed SiO2-Al2O3 inorganic residues has rarely been systematically discussed in prior reports. This study presents an organic–inorganic hybrid flame retardant, SPDP-PTMS@ATH, synthesized by grafting N,P,Si-containing organic groups onto Al(OH)3. The modified ATH retained its layered structure, as confirmed by FTIR, XPS, SEM, and XRD. At only 5 wt.% loading in epoxy, the additive significantly enhanced flame retardancy and smoke suppression: LOI increased to 33.5% (34% higher than pure EP), UL-94 reached V-0 rating, and peak HRR, THR, COPR, TSR, CO2PR, and SPR are reduced by 30.2%, 30.8%, 33.1%, 26.9%, 25.86%, and 15%, respectively. Char analysis revealed a denser, more graphitized structure with fewer defects. Moreover, tensile strength and elongation at break improved by 22.0% and 47.5%, respectively. This work demonstrates that low-loading SPDP-PTMS@ATH simultaneously boosts fire safety, smoke suppression, and mechanical performance, offering a cost-effective and sustainable route to high-performance epoxy composites.

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