Polydopamine-primed FeCo-LDH endowed epoxy resin with enhanced flame retardancy and mechanical properties

The integration of layered double metal hydroxides (LDH) into epoxy resin (EP) for flame retardancy is in line with the principles of environmentally friendly and sustainable development. In this study, polydopamine (PDA)-primed intercalated LDH containing iron and cobalt ions (LDH-DBS@PDA) was prepared, and its chemical composition, structure and morphology were thoroughly characterized. Due to the synergistic flame-retardant properties exhibited by LDH and PDA, as well as the catalytic charring properties of iron and cobalt ions in both condensed and gaseous phases, EP composite with 5 wt% LDH-DBS@PDA achieved a UL-94 V-0 rating with a limiting oxygen index of 30.7 %. Moreover, EP/LDH-DBS@PDA exhibited a significant decrease in total heat release by 48 % and smoke release by 52 %, demonstrating remarkable fire safety performance. Additionally, the existence of LDH-DBS@PDA improved impact strength, tensile strength, and glass transition temperature due to strong interactions between PDA and EP matrix. This work presents a promising strategy for developing highly efficiency flame retardants with excellent compatibility for polymeric materials. •LDH-DBS@PDA has been prepared as an efficient modifier in flame retardancy and mechanical properties for epoxy resin.•EP/LDH-DBS@PDA composites exhibit a reduction of 58 % in PHRR, 48 % in the total THR, and 52 % in TSP.•EP/LDH-DBS@PDA composites exhibit superior performance in impact strength, tensile strength and Tg.