Phosphotungstic Acid Intercalated MgAlLa Ternary Layered Double Hydroxides as High-Efficiency Additives for Epoxy Resin: Synergistic Enhancement of Flame Retardancy and Smoke Suppression

The inherent flammability and toxic smoke emission of epoxy resins (EPs) pose significant challenges to their advanced engineering applications. To address this limitation, we developed a novel flame-retardant additive through the organic modification of layered double hydroxides (LDHs) using a ternary MgAlLa hydrotalcite structure intercalated with phosphotungstic acid (PWA). This innovative design established a synergistic mechanism by combining the catalytic carbonization effect of lanthanum with the radical scavenging capability of PWA. The optimized MgAlLa-PWA/EP composite demonstrated remarkable flame retardancy and smoke suppression improvements, exhibiting 77.9% and 62.4% reductions in the peak heat release rate (pHRR) and total heat release (THR), respectively, compared to pure EP. Particularly noteworthy was the 72.6% decrease in total smoke release (TSR), accompanied by a significant elevation of the limiting oxygen index (LOI) value to 26.8% and achievement of UL-94 V-0 rating. Microstructural analysis revealed that the modified composite formed a continuous and uniform layer with increased density during combustion, effectively inhibiting oxygen exchange, smoke diffusion, and heat transfer. This study provides a novel strategy for designing multi-element synergistic LDHs additive for high-efficiency flame retardancy and smoke suppression of EP.