Advanced Phosphorus–Protein Hybrid Coatings for Fire Safety of Cotton Fabrics, Developed Through the Layer-by-Layer Assembly Technique

Abstract

An advanced, eco-friendly, and fully bio-based flame retardant (FR) system has been created and applied to the cellulose structure of the cotton fabric through a layer-by-layer coating method. This study examines the flame-retardant mechanism of protein-based and phosphorus-containing coatings to improve fire resistance. During combustion, the phosphate groups (−PO₄2−) in phosphorus containing flame retardant layers interact with the amino groups (–NH2) of protein, forming ester bonds, which results in the generation of a crosslinked network between the amino groups and the phosphate groups. This structure greatly enhances the thermal stability of the residual char, hence improving fire resistance. Cone calorimeter and flammability tests show significant improvements in fire safety, including lower peak heat release rates, reduced smoke production, and higher char residue, all contributing to better flame-retardant performance. pHRR, THR, and TSP of the flame-retarded cotton fabric demonstrated 25, 54, and 72% reduction, respectively. These findings suggest that LbL-assembled protein–phosphorus-based coatings provide a promising, sustainable solution for creating efficient flame-retardant materials. © 2025 by the authors.