Eco-friendly flame-retardant epoxy composite using tannic acid and upcycled carbon black via mechano-fusion

In response to the urgent need for sustainable and environmentally friendly materials, this study focuses on enhancing the flame retardancy and mechanical properties of epoxy composites using eco-friendly, non-halogen flame-retardant hybrid fillers. These fillers are synthesized from tannic acid (TA) and upcycled carbon black derived from waste tires (WT-CB) via a mechano-fusion process. The resulting TA/WT-CB fillers exhibit a core–shell structure, with WT-CB uniformly coating the TA surface, significantly improving flame retardancy compared to TA alone. When incorporated into epoxy resin, the TA/WT-CB fillers not only enhance flame resistance but also improve the composite’s mechanical properties. Optimal performance was observed at a filler content of 5 wt.%, where the composite demonstrated superior flame retardancy and mechanical strength. This innovative approach not only addresses fire safety concerns but also promotes sustainability by utilizing upcycled waste materials, offering a promising solution for environmentally conscious flame-retardant technologies.