Single-component flame-retardant and smoke-suppressive epoxy resins enabled by an aluminum/phosphorus/imidazole-containing complex

To simplify the manufacture and address the intrinsic flammability of epoxy resin (EP) products, the single-component, fire-safe EP systems are increasingly in demand. However, current design strategy is difficult to achieve the simultaneous improvement in storage stability, flame retardancy and smoke suppression. Herein, a phosphorus/imidazole-containing, aluminum-based complex (ADIM) was synthesized, and applied as a latent curing agent for EP. The shelf life of EP/ADIM system reached 30 days, and its gel time at 150 °C was only 42 min, indicative of great thermal latency and fast curing rate. EP/ADIM thermoset showed superior flame retardancy, as confirmed by a limiting oxygen index (LOI) of 35.0% and a UL-94 V-0 classification. In addition, the total smoke production and maximum smoke density of EP/ADIM thermoset were 38.7% and 22.3% lower than those of EP thermoset cured by imidazole (EP/IM), demonstrating obviously-enhanced smoke suppression. ADIM inhibited the heat release and smoke generation of the EP matrix via radical capturing and catalytic charring. Moreover, EP/ADIM thermoset exhibited comparable thermal resistance and mechanical properties to EP/IM thermoset. Hence, this work offers an integrated design strategy for creating high-performance, fire-safe, single-component EP with well-preserved mechanical and thermal properties.