Improving flame retardancy in BADGE epoxy via novel phosphorus‐functionalized epoxy integration

A novel epoxy resin, DPHP, was synthesized from diphenolic acid, which contains biobased levulinic acid, with triethylphosphite, to improve the flame retardancy of bisphenol‐A diglycidyl ether (BADGE) epoxy. Curing experiments were conducted using isophorone diamine as a curing agent for BADGE and DPHP mixtures. Variations in cure kinetics, mechanical properties, and flame retardancy were evaluated across different DPHP contents. The introduction of phosphorus functional groups into DPHP affected the polarization of epoxide CO bonds, resulting in reduced apparent activation energy for epoxy curing reactions. However, the higher epoxy equivalent weight of DPHP compared with that of BADGE led to a decrease in the tensile strength and the glass transition temperature of the cured material with increasing DPHP content. A significant increase in char yield for combustion of the epoxy blend was observed, ranging from 8.3% at 0 wt% DPHP to 20.1% at 50 wt% DPHP. Additionally, cone calorimeter measurements showed significant reductions in heat release rate and total heat release, leading to a decrease in fire spread from 1.07 MJm−2 s−1 at 0 wt% DPHP to 0.43 MJm−2 s−1 at 50 wt% DPHP. These results show that the flame retardancy of the cured material improved significantly as the DPHP content increased. Blending bisphenol‐A diglycidyl ether epoxy (BADGE) with a novel phosphorus‐functionalized epoxy (DPHP) reduces the total heat release rate.