Synergistic Adenosine Triphosphate/Chitosan Bio-coatings on Polyurethane Foam for Simultaneously Improved Flame Retardancy and Smoke Suppression

Considering that fire safety is a persistent problem for most polymeric materials, including polyurethane (PU) foam, the demand for flame retardants (FRs) is growing. However, the use of conventional FRs containing halogenated and brominated chemicals has been continuously regulated owing to their toxicity. Here, we demonstrate the layer-by-layer (LbL) coating of negatively charged adenosine triphosphate (ATP) and positively charged chitosan (CS) as the synergistic FR on PU foam, a model flammable polymer material. The FR performance of the PU coated with LbL-assembled ATP and CS (ATP/CS-PU) was tested, and the results suggested that the ATP/CS layers were finely deposited on the surface of the PU without damaging the structure. Only five bilayers (5BL) were sufficient to impart excellent fire retardancy, which exhibited a limiting oxygen index value of 35% and the HF-1 rating in the UL94 foamed material horizontal burning test. In addition, ATP/CS(5BL)-PU showed a significant reduction in the peak heat release rate of 42.0% and in the total smoke release of 30.6% compared to that of bare PU (b-PU). Furthermore, the ATP/CS coatings did not deteriorate the mechanical properties of b-PU. Finally, combined thermogravimetry-Fourier transform infrared spectroscopy (TG-FTIR) showed that ATP/CS(5BL)-PU was safe because it suppresses hazardous gases, which is the main problem with conventional FRs.