Synthesis of three novel phosphorus-containing flame retardants and their application in epoxy resins

One symmetric diamine (4) and two symmetric phenols (5) and (6) were synthesized as phosphorus-containing flame retardants. The synthesis comprised a two-step procedure: the condensation of p-phenylenediamine with benzaldehyde, 4-hydroxybenzaldehyde and 2-hydroxybenzaldehyde respectively, followed by the addition of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide to the imine linkage. The structures of (4)-(6) were characterized by FTIR, NMR and mass spectra. (4)-(6) served as co-curing agents of diaminodiphenylmethane for epoxy resins, and epoxy thermosets exhibited excellent flame retardancy, moderate changes in glass transition temperature (Tg) and thermal stability. When the phosphorus content reached 1.0 wt.%, the epoxy resin system met the UL-94 V-0 classification and the limiting oxygen index (LOI) reached more than 35.6, probably because of the nitrogen-phosphorus synergistic effect.