A Multifunctional Cationic Waterborne Polyurethane System with High Fire-Safety and Antibacterial Performance Enabled...

Waterborne polyurethane (WPU) is widely used in flexible films and textile finishing, but its intrinsic flammability, severe melt dripping, and sensitivity to polar additives restrict its fire-safe applications. Herein, a phosphorous acid-protonated chitosan (PCS) was designed as an emulsion-adaptable bio-based modifier and incorporated into cationic WPU via a facile aqueous blending route, yielding transparent multifunctional composite films and flame-retardant textile coatings. Unlike conventional flame-retardant WPU systems that rely on reactive monomers or suffer from poor emulsion compatibility, this work proposes an emulsion-compatible strategy based on PCS, enabling the simultaneous integration of dispersion stability, flame retardancy, and antibacterial functionality within a single system. PCS could be stably accommodated in the WPU latex without visible precipitation or demulsification after centrifugation, and the resulting films preserved a continuous matrix structure with uniformly distributed PCS-rich nanodomains. Rheological analyses revealed that the polar groups of PCS established strong intermolecular associations with urethane segments, strengthening the physical network. The char residue at 700 °C increased from 0.7 wt% for neat WPU to 32.7 wt% for WPU/PCS-5. Meanwhile, WPU/PCS-5 achieved a limiting oxygen index of 35.4% and a UL-94 V-0 rating, while its peak heat release rate and total heat release were reduced by 73.4% and 41.8%, respectively. The composite films also showed nearly complete antibacterial efficiency against Escherichia coli and Staphylococcus aureus. As a textile coating, WPU/PCS-5 enabled immediate self-extinguishing of cotton fabric, increased the limiting oxygen index from 18.5% to 27.2%, and reduced the damaged length from 30.0 to 11.0 cm. This work demonstrates that an emulsion-compatible strategy based on PCS can effectively integrate dispersion stability, fire safety, multifunctionality, and coating applicability into WPU materials.