Epoxy Blends Containing Melamine Phosphate-Based Flame Retardants: Thermal and Flammability Performance

Epoxy resins are widely used in advanced engineering applications, including coatings, adhesives, and electronics. Therefore, improving their flame resistance is important for enhancing fire safety and extending their range of applications. A series of flame retardants based on melamine phosphate derivatives, such as melamine phosphate (MP), melamine dibutyl phosphate, and melamine bis(2-ethylhexyl) phosphate, as well as a zinc borate-modified system (ZnB-MP) has been incorporated into commercially available epoxy resin (Epidian® 601). The blends were characterized using Fourier transform infrared spectroscopy (FTIR) to confirm their chemical structure. Thermal behaviour was investigated using differential scanning calorimetry and thermogravimetry coupled with FTIR gas analysis (TG-FTIR). The flammability performance of the epoxy blends was evaluated using pyrolysis combustion flow calorimetry, which allowed parameters such as heat release rate, total heat release, and heat release capacity to be determined. The incorporation of melamine phosphate-based flame retardants was found to significantly reduce the flammability of epoxy blends, leading to substantial decreases in heat release rate, total heat release, and heat release capacity. The most pronounced effect was observed in systems containing higher concentrations of MP and in cooperative ZnB-MP formulations.