Synthesis of a Bimetallic-Doped Phytate-Melamine Composite as an Efficient Additive for Epoxy Resins with High Fire Safety

The issue of hazardous smoke and toxic gases released from epoxy resins (EP), which often causes casualties in real fires, has limited its application. Therefore, we have developed a novel flame retardant based on a bimetallic-doped phytate-melamine (BPM) structure with Zn²⁺ and Fe²⁺ ions incorporated into the polymer matrix using a straightforward solution-based synthetic method. The combustion performance of the composite was evaluated using a cone calorimeter test, which showed that the peak heat release, total heat release, and total smoke production were reduced by 50%, 31.7%, and 29.2%, respectively, compared to those of EP. Additionally, the fire growth index was noticeably reduced by 60% owing to the synergistic catalytic effect of the bimetallic ions, and the high nitrogen and phosphorus content of the additives. Overall, this study provides new insights into the application of bimetallic doping for flame retardant polymer composites.