Diaminodiphenylmethane modified zirconium phosphate: A new strategy for trace addition to improve flame retardancy, smoke inhibition, and compatibility of epoxy resins.

High‐efficient flame retardants (ZrP‐DDM) were synthesized successfully via ion‐exchange method, using diaminodiphenylmethane (DDM) modified layered zirconium phosphate (α‐ZrP). Trace addition of ZrP‐DDM in epoxy resins (EP) can enhance the flame‐retardant, smoke‐inhibition, mechanical, and thermal stability properties of EP composites. As shown in the results, ZrP‐DDM exhibits a better synergistic effect than α‐ZrP, and the EP composites containing 0.5 wt% ZrP‐DDM (EP/0.5ZrP‐DDM) show excellent flame‐retardant and smoke‐inhibition properties. Especially, EP/0.5ZrP‐DDM possesses a limiting oxygen index (LOI) of 33.7% with UL94 V‐1 rating, while the EP composites containing 0.5 wt% ZrP (EP/0.5ZrP) has a LOI of 30.1% and fails to achieve the UL94 rating. Furthermore, the peak heat release rate (PHRR), total heat release rate (THR), and smoke density rating of EP/0.5ZrP‐DDM decrease by 10.2%, 3.7%, and 8.2% compared with EP/0.5ZrP. Based on condensed‐phase product analysis, EP/ZrP‐DDM sample provides a gas source for intumescent char layer, and produces a stable phosphorus‐rich crosslinking structures during combustion, thus decreasing the fire hazard of the composite material. Meanwhile, the introduction of ZrP‐DDM has a less impact on tensile strength of EP composites compared with α‐ZrP, suggesting the addition of ZrP‐DDM effectively enhances the compatibility with the EP matrix, thereby maintaining excellent mechanical properties of the EP matrix. [ABSTRACT FROM AUTHOR]