Phosphorus–Silicon Additive Increases the Mechanical and Fire Resistance of Epoxy Resins

Epoxy resins are limited by their flammability and brittleness. In this study, a phosphorus- and silicon-based additive was synthesized to improve fire resistance and mechanical performance. The incorporation of just 1 wt% phosphorus from this additive into epoxy resin achieved a limiting oxygen index of 33% and a V-0 fire rating. The modified epoxy exhibited a 52.43% reduction in the peak heat release rate and a 35.70% decrease in total smoke production compared to the unmodified resin, demonstrating enhanced heat resistance and smoke suppression. Notably, the modified epoxy thermoset displayed superior mechanical properties, with tensile and impact strengths increasing by 48.41% and 130%, respectively. This research presents a promising approach for developing high-performance epoxy resins with improved flame retardancy, smoke suppression, and mechanical strength.