The development of epoxy resin (EP) with simultaneous enhancements in flame retardancy, mechanical performance, and low dielectric properties represents a significant and complex challenge. In this study, halloysite nanotubes (HNTs) were modified with melamine amino tris-methylene phosphonate (MA) to produce MA-modified HNTs (HMA), which were then integrated into EP to form EP/HMA composites. The incorporation of 1 wt% HMA significantly enhanced the flame retardancy (limit oxygen index up to 29.7%, UL-94 V-0 rating), reduced peak heat release rate by 23.4%, decreased total heat release by 11.9%, reduced total smoke production by 18.4%, and improved mechanical properties (tensile strength by 17.0%, impact strength by 61.0%) compared to pure EP. Additionally, EP/HMA showed a low dielectric constant (3.16) and a dielectric loss (0.019) at 1 GHz. This research presents a versatile strategy for creating multifunctional EP composites with high potential for applications in microelectronics, electronic packaging, and other relevant fields.
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