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Advanced Epoxy-Based Materials III

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A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Applications".

Deadline for manuscript submissions: closed (15 December 2022) | Viewed by 22932

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Prof. Dr. Keon-Soo Jang

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Department of Polymer Engineering, School of Chemical and Materials Engineering, The University of Suwon, 17 Wauan-gil, Bongdam-eup, Hwaseong 18323, Republic of Korea
Interests: functional epoxy resins for electronics packaging; extrusion; polymer composites
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Dear Colleagues,

Epoxy resins are now broadly used in electronic applications due to their beneficial properties, such as excellent adhesion, low shrinkage, low dielectric constant, and outstanding mechanical and thermal properties. Advanced epoxy-based materials may include metal/epoxy, carbon-based fillers/epoxy, inorganic materials/epoxy, epoxy/polymeric materials, and fiber-reinforced epoxy composites. Advanced epoxy-based materials have a wide range of applications, such as use as adhesives for electronic devices, bio-based epoxy resins, paints/coatings, wind turbine composites, automotive/aerospace composites, and other adhesives for numerous applications. This Special Issue is highly motivated by the enlarged scope of utilization of advanced epoxy-based materials and will pay significant attention to new synthetic methods, compositions, functionalization/modification, structure–property relationships, and biomedical and energy applications.

Considering your prominent contributions to this field, I would like to cordially invite you to submit an article to this Special Issue. This Special Issue will publish full research papers, communications, and review articles. I would like to bring together a collection of comprehensive reviews from leading experts and up-to-date research from notable groups in the community.

Manuscripts can be submitted now up until the deadline and will be published on an ongoing basis. I would greatly appreciate your contribution to this Special Issue.

Prof. Dr. Keon-Soo Jang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

thermoset polymers
epoxy composites
nanocomposites
synthesis
functionalization
characterization
electronic packaging
automotive
aerospace

Related Special Issue

Advanced Epoxy-Based Materials, 5th Edition in Polymers

Published Papers (13 papers)

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Research

12 pages, 2516 KiB

Open AccessArticle

Highly Toughened Nanostructured Self-Assembled Epoxy-Based Material—Correlation Study between Nanostructured Morphology and Fracture Toughness—Impact Characteristics

by Vasudevan Pillay Remya, Sundararajan Parani, El Hadji Mamour Sakho, Jose Varghese Rajendran, Rodney Maluleke, Thabang Calvin Lebepe, Sam Masha, Nishar Hameed, Sabu Thomas and Oluwatobi Samuel Oluwafemi

Polymers 2023, 15(7), 1689; https://doi.org/10.3390/polym15071689 - 28 Mar 2023

Cited by 1 | Viewed by 1396

Abstract

We present an efficient and effective method for preparing a novel self-assembled nanostructured material with high toughness and impact strength from a blend of di-glycidyl ether of bisphenol-A (DGEBA) and epoxidized poly(styrene-block-butadiene-block-styrene) (eSBS₅₅) tri-block copolymer. The field emission scanning electron microscopy and transmission electron microscope results show the nanostructured morphological characteristics of the blends. This study achieved the highest fracture toughness, with a fracture toughness in the form of critical stress intensity factors (K_IC) value of 2.54 MPa m^1/2, in epoxy/block copolymer blends compared to previous works in the field. The impact strength also increased by 116% compared to neat epoxy. This is a major advancement in epoxy toughening due to the use of a single secondary phase. The resulting highly tough and impact-resistant material is a promising candidate for coating applications in industries such as flooring, building, aerospace, and automobiles. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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28 pages, 6021 KiB

Open AccessArticle

Solid Particle Erosion of Filled and Unfilled Epoxy Resin at Room and Elevated Temperatures

by Maxim Mishnev, Alexander Korolev, Dmitrii Ulrikh, Anna Gorechneva, Denis Sadretdinov and Danila Grinkevich

Polymers 2023, 15(1), 1; https://doi.org/10.3390/polym15010001 - 20 Dec 2022

Cited by 2 | Viewed by 1223

Abstract

Solid particle erosion at room and elevated temperatures of filled and unfilled hot-cured epoxy resin using an anhydride hardener were experimentally tested using an accelerated method on a special bench. Micro-sized dispersed industrial wastes were used as fillers: fly ash from a power plant and spent filling material from a copper mining and processing plant. The results showed that the wear of unfilled epoxy resin significantly decreases with increasing temperature, while the dependence on the temperature of the wear intensity at an impingement angle of 45° is linear and inversely proportional, and at an angle of 90°, non-linear. The decrease in wear intensity is probably due to an increase in the fracture limit because of heating. Solid particle erosion of the filled epoxy compounds is considerably higher than that of unfilled compounds at impingement angles of 45° and 90°. Filled compounds showed ambiguous dependences of the intensity of wear on temperature (especially at an impingement angle of 45°), probably as the dependence is defined by the filler share and the structural features of the samples caused by the distribution of filler particles. The intensity of the wear of the compounds at impingement angles of 45° and 90° has a direct and strong correlation with the density and the modulus of elasticity, and a weak correlation with the bending strength of the materials. The data set for determining the correlation between the mechanical properties and the wear included compound filling characteristics and temperature. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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17 pages, 6597 KiB

Open AccessArticle

An Experimental Investigation into Mechanical and Thermal Properties of Hybrid Woven Rattan/Glass-Fiber-Reinforced Epoxy Composites

by Agustinus Purna Irawan, Paula Tjatoerwidya Anggarina, Didi Widya Utama, Najid Najid, Mohd Zulkfly Abdullah, Januar Parlaungan Siregar, Tezara Cionita, Deni Fajar Fitriyana, Jamiluddin Jaafar, Agung Efriyo Hadi and Teuku Rihayat

Polymers 2022, 14(24), 5562; https://doi.org/10.3390/polym14245562 - 19 Dec 2022

Cited by 8 | Viewed by 2366

Abstract

The investigation of hybrid, woven, natural fiber-reinforced polymer composites as a substitute reinforcement for fiber polymer composites has recently caught the interest of academics, industry, and researchers. Woven, natural fiber composites have been implemented in many different applications, including parts for automobiles, household items, flooring, aerospace, and ballistic materials. Therefore, this research seeks to establish the thermal and mechanical characteristics of composites made from rattan strips (RS) and glass fiber (GF)-reinforced epoxy resin (ER). Other than that, the impact of layering configurations with respect to the thermal and mechanical characteristics of the RS and GF will be determined. Hand lay-up and a hydraulic press machine produce hybrid, woven RS and GF laminates. The hybrid composite’s mechanical properties will be investigated using impact, tensile, and flexural tests. The hybrid woven of the GF/RS/RS/RS/GF composite sequence demonstrated the highest mechanical properties in comparison to other sequences. The increase from one to three layers of RS in the core layer of GF hybrid composites enhanced the flexural, impact, and tensile properties. In addition, the hybridization of rattan and GF is more thermally stable, as recorded by the high decomposition temperature. As a finding of the research, the woven RS and GF hybrid is a potential material for automotive applications such as car bumpers, for example. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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23 pages, 6490 KiB

Open AccessArticle

Performance Evaluation for Ultra-Lightweight Epoxy-Based Bipolar Plate Production with Cycle Time Reduction of Reactive Molding Process

by Budsaba Karoonsit, Rungsima Yeetsorn, Darunee Aussawasathien, Walaiporn Prissanaroon-Ouajai, Gaurav Kumar Yogesh and Yaowaret Maiket

Polymers 2022, 14(23), 5226; https://doi.org/10.3390/polym14235226 - 01 Dec 2022

Cited by 4 | Viewed by 1673

Abstract

The commercial viability of fuel cells for vehicle application has been examined in the context of lightweight material options, as well as in combination with improvements in fuel cell powertrain. Investigation into ultra-lightweight bipolar plates (BPs), the main component in terms of the weight effect, is of great importance to enhance energy efficiency. This research aims to fabricate a layered carbon fiber/epoxy composite structure for BPs. Two types of carbon fillers (COOH-MWCNT and COOH-GNP) reinforced with woven carbon fiber sheets (WCFS) have been utilized. The conceptual idea is to reduce molding cycle time by improving the structural, electrical, and mechanical properties of BPs. Reducing the reactive molding cycle time is required for commercial production possibility. The desired crosslink density of 97%, observed at reactive molding time, was reduced by 83% at 140 °C processing temperature. The as-fabricated BPs demonstrate excellent electrical conductivity and mechanical strength that achieved the DOE standard. Under actual fuel cell operation, the as-fabricated BPs show superior performance to commercial furan-based composite BPs in terms of the cell potential and maximum power. This research demonstrates the practical and straightforward way to produce high-performance and reliable BPs with a rapid production rate for actual PEMFC utilization. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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14 pages, 2512 KiB

Open AccessFeature PaperArticle

Biological Effects and Toxicity of Compounds Based on Cured Epoxy Resins

by Anna Rudawska, Katarzyna Sarna-Boś, Adrianna Rudawska, Ewa Olewnik-Kruszkowska and Mariaenrica Frigione

Polymers 2022, 14(22), 4915; https://doi.org/10.3390/polym14224915 - 14 Nov 2022

Cited by 8 | Viewed by 1841

Abstract

The aim of this work was to investigate selected biological and toxicity properties of cured epoxy resin-based compounds based on a bisphenol A epoxy resin, cold-cured by a polyamide and containing two types of metal powders (aluminum and copper). This study involved cytotoxicity analysis, pH measurements, absorbance measurements and sterilization. The cytotoxicity analysis was conducted to determine the harmful degree of the cured epoxy resin. Aimed at identifying toxic agents in cured compounds, the cytotoxicity analysis involved absorbance measurements in an entire wavelength range. Cytotoxicity and absorbance results demonstrated that the extracts of all the tested resin samples had no cytotoxic effects on the cells of living organisms. The absorbance values obtained over the entire wavelength range did not point to the formation of aggregations, which proved that no toxic agents harmful to living organisms were extracted from the resin samples. Based on the results obtained, it can be concluded that all tested compounds, based on epoxy resins, which are also used as adhesives in various applications, are essentially safe materials when using such formulations in a cured state. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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19 pages, 4342 KiB

Open AccessArticle

Multifunctional Performance of Hybrid SrFe₁₂O₁₉/BaTiO₃/Epoxy Resin Nanocomposites

by Georgia C. Manika, Sevasti Gioti, Aikaterini Sanida, Georgios N. Mathioudakis, Anxhela Abazi, Thanassis Speliotis, Anastasios C. Patsidis and Georgios C. Psarras

Polymers 2022, 14(22), 4817; https://doi.org/10.3390/polym14224817 - 09 Nov 2022

Cited by 2 | Viewed by 1529

Abstract

Polymer matrix nanocomposites are widely studied because of the versatility of their physical and mechanical properties. When these properties are present simultaneously, responding at relative stimuli, multifunctional performance is achieved. In this study, hybrid nanocomposites of SrFe₁₂O₁₉ and BaTiO₃ ceramic particles dispersed in an epoxy resin matrix were fabricated and characterized. The content of SrFe₁₂O₁₉ was varying, while the amount of BaTiO₃ was kept constant. The successful fabrication of the nanocomposites and the fine dispersion of the ceramic particles was verified via the morphological and structural characterization carried out with X-ray Diffraction patterns and Scanning Electron Microscopy images. Dielectric response and related relaxation phenomena were studied by means of Broadband Dielectric Spectroscopy. Dielectric permittivity augments with filler content, while the recorded relaxations, with descending relaxation time, are: (i) interfacial polarization, (ii) glass-to-rubber transition, (iii) intermediate dipolar effect, and (iv) re-orientation of polar-side groups of the main polymer chain. SrFe₁₂O₁₉ nanoparticles induce magnetic properties to the nanocomposites, which alter with the magnetic filler content. Static and dynamic mechanical response improves with filler content. Thermogravimetric analysis shown that ceramic particles are beneficial to the nanocomposites’ thermal stability. Glass transition temperature, determined via Differential Scanning Calorimetry, was found to slightly vary with filler content, in accordance with the results from dynamic mechanical and dielectric analysis, indicating the effect of interactions occurring between the constituents. Examined systems are suitable for energy storing/retrieving. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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12 pages, 2944 KiB

Open AccessArticle

Effect of Kaolin Clay and ZnO-Nanoparticles on the Radiation Shielding Properties of Epoxy Resin Composites

by Mahmoud I. Abbas, Abdullah H. Alahmadi, Mohamed Elsafi, Sultan A. Alqahtani, Sabina Yasmin, M. I. Sayyed, Mona M. Gouda and Ahmed M. El-Khatib

Polymers 2022, 14(22), 4801; https://doi.org/10.3390/polym14224801 - 08 Nov 2022

Cited by 6 | Viewed by 1673

Abstract

The use of radiation is mandatory in modern life, but the harms of radiation cannot be avoided. To minimize the effect of radiation, protection is required for the safety of the environment and human life. Hence, inventing a better shield than a conventional shielding material is the priority of researchers. Due to this reason, this current research deals with an innovative shielding material named EKZ samples having a composition of (epoxy resin (90–40) wt %-kaolin clay (10–25) wt %-ZnO-nano particles (0–35) wt %). The numerous compositional variations of (epoxy resin, kaolin clay, and ZnO-nano particles on the prepared EKZ samples varied the density of the samples from 1.24 to 1.95 g/cm³. The radiation shielding parameter of linear attenuation coefficient (LAC), half value layer (HVL), tenth value layer (TVL), and radiation protection efficiency (RPE) were measured to evaluate the radiation diffusion efficiency of newly made EKZ samples. These radiation shielding parameters were measured with the help of the HPGe detector utilizing the three-point sources (Am-241, Cs-137, and Co-60). The obtained results exposed that the value of linear attenuation coefficient (LAC) and radiation protection efficiency (RPE) was maximum, yet the value of half value layer (HVL), and tenth value layer (TVL), were minimum due to the greater amount of kaolin clay and ZnO-nanoparticles, whereas the amount of epoxy resin was lesser. In addition, it has been clear that as-prepared EKZ samples are suitable for low-dose shielding applications as well as EKZ-35 showed a better shielding ability. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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16 pages, 7683 KiB

Open AccessArticle

The Effect of Flame Retardant—Aluminum Trihydroxide on Mixed Mode I/II Fracture Toughness of Epoxy Resin

by Paweł Zielonka, Szymon Duda, Grzegorz Lesiuk, Wojciech Błażejewski, Magdalena Wiśniewska, Joanna Warycha, Paweł Stabla, Michał Smolnicki and Bartosz Babiarczuk

Polymers 2022, 14(20), 4386; https://doi.org/10.3390/polym14204386 - 17 Oct 2022

Cited by 2 | Viewed by 1936

Abstract

Fire resistance is a major issue concerning composite materials for safe operation in many industrial sectors. The design process needs to meet safety requirements for buildings and vehicles, where the use of composites has increased. There are several solutions to increasing the flame resistance of polymeric materials, based on either chemical modification or physical additions to the material’s composition. Generally, the used flame retardants affect mechanical properties either in a positive or negative way. The presented research shows the influence of the mixed-mode behavior of epoxy resin. Fracture toughness tests on epoxy resin samples were carried out, to investigate the changes resulting from different inorganic filler contents of aluminum trihydroxide (ATH). Three-point bending and asymmetric four-point bending tests, with different loading modes, were performed, to check the fracture behavior in a complex state of loading. The results showed that the fracture toughness of mode I and mode II was reduced by over 50%, compared to neat resin. The experimental outcomes were compared with theoretical predictions, demonstrating that the crack initiation angle for higher values of KI/KII factor had a reasonable correlation with the MTS prediction. On the other hand, for small values of the factor K_I/K_II, the results of the crack initiation angle had significant divergences. Additionally, based on scanning electron microscopy images, the fracturing of the samples was presented. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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13 pages, 4391 KiB

Open AccessArticle

Molecular Simulations and Network Analyses of Surface/Interface Effects in Epoxy Resins: How Bonding Adapts to Boundary Conditions

by Julian Konrad, Paolo Moretti and Dirk Zahn

Polymers 2022, 14(19), 4069; https://doi.org/10.3390/polym14194069 - 28 Sep 2022

Cited by 2 | Viewed by 1390

Abstract

In this study, we unravel the atomic structure of a covalent resin near boundaries such as surfaces and composite constituents. For this, a molecular simulation analysis of epoxy resin hardening under various boundary conditions was performed. On the atomic level of detail, molecular dynamics simulations were employed to study crosslinking reactions and self-organization of the polymer network within nm scale slab models. The resulting structures were then coarsened into a graph theoretical description for connectivity analysis of the nodes and combined with characterization of the node-to-node vector orientation. On this basis, we show that the local bonding of epoxy resins near interfaces tends to avoid under-coordinated linker sites. For both epoxy–vacuum surface models and epoxy–silica/epoxy cellulose interfaces, we find almost fully cured polymer networks. These feature a local increase in network linking lateral to the surface/interface, rather than the dangling of unreacted epoxy groups. Consequently, interface tension is low (as compared to the work of separating bulk epoxy), and the reactivity of the resin surface appears negligible. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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13 pages, 3722 KiB

Open AccessArticle

Determination of Translaminar Notch Fracture Toughness for Laminated Composites Using Brazilian Disk Test

by Ali Reza Torabi, Mohammad Amin Motamedi, Bahador Bahrami, Meghdad Noushak, Sergio Cicero and José Alberto Álvarez

Polymers 2022, 14(16), 3246; https://doi.org/10.3390/polym14163246 - 09 Aug 2022

Cited by 4 | Viewed by 1440

Abstract

This paper evaluates the fracture of notched epoxy matrix composites using the Brazilian disk (BD) test from both numerical and experimental points of view. The study began with a comprehensive experimental program covering three different composite lay-ups (quasi-isotropic, unidirectional, and cross-ply) and various geometries of U and V notches. Specifically, the BD samples combined the three layouts, four different notch angles, and three notch radii with three specimens per combination, leading to an overall number of 108 fracture tests. The experiments showed the appropriateness of the BD test for the study of the fracture behavior of composite materials and provided a good pool of data for further investigations. Subsequently, the virtual isotropic material concept (VIMC) was applied in combination with two fracture criteria to theoretically predict the experimentally acquired fracture loads. This study demonstrated that using the VIMC approach can provide robust predictions while incurring much lower computational costs compared to the conventional approaches found in the literature. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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17 pages, 4115 KiB

Open AccessArticle

The Influence of Filler Loading and Alkaline Treatment on the Mechanical Properties of Palm Kernel Cake Filler Reinforced Epoxy Composites

by Tezara Cionita, Januar Parlaungan Siregar, Wong Ling Shing, Cheng Wan Hee, Deni Fajar Fitriyana, Jamiluddin Jaafar, Ramli Junid, Agustinus Purna Irawan and Agung Efriyo Hadi

Polymers 2022, 14(15), 3063; https://doi.org/10.3390/polym14153063 - 28 Jul 2022

Cited by 10 | Viewed by 1864

Abstract

The manufacturing of materials, in conjunction with green technology, emphasises the need to employ renewable resources to ensure long-term sustainability. Re-exploring renewable elements that can be employed as reinforcing materials in polymer composites has been a major endeavour. The research goal is to determine how well palm kernel cake filler (PKCF) performs in reinforced epoxy composites. In this study, PKCF with 100 mesh was mixed with epoxy resin (ER) in various ratios ranging from 10% to 40% by weight. Hand lay-up with an open mould is proposed as a method for fabricating the specimen test. Surface modification of PKCF with varying concentrations of NaOH (5 wt.% and 10 wt.%) will be contrasted with the untreated samples. Using Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC), the effect of alkaline treatment will be examined. The tensile and maximum flexural strength of the untreated PKCF/ER composite were determined in this work, with a 30 wt.% of PKCF having the highest tensile strength of 31.20 MPa and the highest flexural strength of 39.70 MPa. The tensile and flexural strength were reduced to 22.90 MPa and 30.50 MPa, respectively, when the filler loading was raised to 40 wt.%. A 5 wt.% alkali treatment for 1 h improved the composites’ mechanical characteristics. Lastly, an alkali treatment can aid in the resolution of the problem of inadequate matrix and filler interaction. Alkaline treatment is a popular and effective method for reducing the hydroxyl group in fillers and, thus, improving interfacial bonding. Overall, palm kernel cake is a promising material used as a filler in polymer composites. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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12 pages, 3244 KiB

Open AccessArticle

Synthesis of Layered Double Hydroxides with Phosphate Tailings and Its Effect on Flame Retardancy of Epoxy Resin

by Hanjun Wu, Wenjun Zhang, Huali Zhang, Pengjie Gao, Lingzi Jin, Yi Pan and Zhiquan Pan

Polymers 2022, 14(13), 2516; https://doi.org/10.3390/polym14132516 - 21 Jun 2022

Cited by 4 | Viewed by 1601

Abstract

In this work, phosphate tailings (PTs) were used as raw materials for the preparation of Ca-Mg-Al layered double hydroxides (LDHs-1) and Ca-Mg-Al-Fe layered double hydroxides (LDHs-2) by co-precipitation method. The as-prepared samples were characterized by FT-IR, SEM, XRD, and XPS and applied as a flame retardant to improve the fire safety of epoxy resin (EP). The results showed that both LDHs-1 and LDHs-2 exhibited layered structure and high crystallinity. Compared with neat EP, the value of limiting oxygen index (LOI) increased from 25.8 to 29.3 and 29.9 with 8 wt% content of LDHs-1 and LDHs-2, respectively. The flame retardant properties of the composite material were characterized by cone calorimeter (CC), and the results showed that the peak value of the smoke production rate (SPR) decreased more than 45% and 74%, total smoke production (TSP) reduced nearly 64% and 85% with the addition of LDHs-1 and LDHs-2. Meanwhile, the value of the total heat release (THR) reduced more than 28% and 63%. The conversion from LDHs to layered double oxide (LDO) might be conducive to the fire safety of EP. Moreover, the transformation of Fe-OH to Fe-O could promote the early cross-linking of polymer. In summary, LDHs-2 could significantly improve the carbonization process of EP and suppress the smoke released during the combustion process. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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15 pages, 6703 KiB

Open AccessArticle

Facile Construction of Polypyrrole Microencapsulated Melamine-Coated Ammonium Polyphosphate to Simultaneously Reduce Flammability and Smoke Release of Epoxy Resin

by Feiyue Wang, Jiahao Liao, Long Yan and Mengtao Cai

Polymers 2022, 14(12), 2375; https://doi.org/10.3390/polym14122375 - 12 Jun 2022

Cited by 12 | Viewed by 2033

Abstract

A unique mono-component intumescent flame retardant, named PPy-MAPP, of which melamine-coated ammonium polyphosphate (MAPP) was microencapsulated by polypyrrole (PPy), was synthesized and carefully characterized. The obtained PPy-MAPP was applied to epoxy resin (EP) for obtaining flame-retarded EP composites. The results show that PPy-MAPP imparts better flame retardancy and smoke suppression properties to EP compared to the same addition of MAPP. The EP composite with 15 wt% PPy-MAPP easily passes the UL94 V-0 rating and achieves an LOI value of 42.4%, accompanied by a 61.9% reduction in total heat release (THR) and a 73.9% reduction in total smoke production (TSP) when compared with pure EP. The char residue analysis shows that PPy-MAPP can promote a generation of more phosphorus-rich structures in the condensed phase that improve the integrity and intumescence of char against fire. The mechanical test indicates that PPy-MAPP has a less negative effect on the tensile strength and elastic modulus of epoxy resin due to the good compatibility between PPy-MAPP and the EP matrix, as supported by differential scanning calorimetry (DSC) analyses. In this paper, these attractive features of PPy-MAPP provide a new strategy to prepare satisfactory flame retardant and super flame retarding EP composites. Full article

(This article belongs to the Special Issue Advanced Epoxy-Based Materials III)

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