Study on multifunctional properties of epoxy resin synergistically modified by intercalated zirconium phosphate, high-entropy oxide, and ultrafine aluminum oxide

The influence of intercalated zirconium phosphate (IZP), high-entropy oxide (HEO), ultrafine aluminum oxide (FAO), and their binary hybrid systems on epoxy resin coatings was evaluated through electrochemical, thermal, electrical, and dielectric tests. The results delineated distinct functional profiles for each filler. IZP excelled as an active corrosion inhibitor and high-frequency dielectric stabilizer, FAO provided outstanding long-term barrier protection and electrical insulation, and HEO exhibited a complex role, enhancing thermal stability but impairing corrosion resistance due to its inherent semiconducting. Crucially, significant synergistic and antagonistic effects were identified upon hybridization. The IZP/HEO combination demonstrated a remarkable “catalysis-stabilization” synergy, increasing the char yield to over six times that of neat epoxy. The HEO/FAO hybrid achieved an optimal balance of enhanced thermal stability and superior electrical insulation. Conversely, HEO universally degraded anti-corrosion performance, and an antagonistic effect between IZP and FAO led to increased dielectric loss. This work constructs a clear “filler-structure-property” relationship map, providing scientific strategies for the rational design of next-generation epoxy coatings tailored for specific demanding applications such as electronic packaging, long-term corrosion protection, or high-temperature shielding.