Mechanically Enhanced Flame Retardant Polyester/Cotton Fabric with Bio-Inspired Phosphorus/Nitrogen Synergistic Coating

Polyester/cotton blended fabrics—valued for comfort and durability—face significant fire hazards due to a synergistic “scaffold effect” during combustion. Conventional treatments with high temperature or some acidic phosphorus flame retardants during preparation often compromise the mechanical strength. Inspired by mussel adhesion chemistry, a mechanically enhanced polyester/cotton fabric was developed by using a novel bio-inspired phosphorus/nitrogen (P/N) synergistic coating. A uniform polydopamine-polyethylenimine (PDA-PEI) layer is rapidly deposited via co-deposition, suppressing dopamine self-polymerization. Subsequent covalent bonding with 2,2-dimethyl-1,3-propanediyl bis (phosphoryl chloride) (DPPC) establishes a robust P/N network. The fabricated PDA-PEI/DPPC coating reduces peak heat release rate (pHRR) and total heat release (THR) by 57.7% and 32.6%, respectively, in cone calorimetry, achieving self-extinguishment and a high limiting oxygen index (LOI) of 24.6%. Remarkably, the coating simultaneously increases the weft-direction breaking strength by 55% and elongation at break by 27.2%; these changes overcome the typical mechanical degradation associated with acidic phosphorus flame retardants. A comprehensive analysis reveals a synergistic mechanism: phosphoric acids catalyze cellulose dehydration and char layer formation in the condensed phase (90% stable C–C bonds), while radical scavengers (PO·, HPO·, and PDA) and non-flammable gases suppressed gas-phase combustion. This work presents a facile and effective strategy for fabricating high-performance and mechanically robust flame retardant polyester/cotton textiles, demonstrating the significant potential for improving fire safety in practical applications.