Acidity regulation of boron phosphate flame retardant and its catalyzing carbonization mechanism in epoxy resin

Boron phosphates (BPs) with different acidities were prepared by regulating the calcination temperatures for the reaction products of boric acid and phosphoric acid. The crystal structure, morphology, surface acidity, and thermal stability were characterized by X-ray diffraction, scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), chemical absorbed apparatus, and thermogravimetric analysis (TG). The effects of BPs on the combustion behavior and catalyzing the carbonization of bisphenol-A epoxy resin (EP) were investigated by the limiting oxygen index (LOI) and cone calorimetry test. Upon loading 5 mass% BP prepared at 300 °C, the LOI value of the EP/BP composites increased to 29.6%, and moreover, the peak heat release rate and average specific extinction area decreased by 43 and 25%, respectively. A possible catalyzing carbonization mechanism was explored by TG coupled with Fourier transform infrared spectroscopy (TG–FTIR), TG, FTIR, SEM, Raman spectroscopy (Raman), and XPS. The results demonstrated that BP catalyzed EP to degrade at relatively low temperature, and the yield, compactness, and graphitization degree of the char residue were obviously enhanced with an increase in the ratio of Bronsted and Lewis acid sites (B/L value) and the total surface acid sites on the BP surface. Therefore, the catalyzing carbonization flame retardancy of the EP/BP composites can be improved through regulating the surface acidity of BP.