Layer-by-layer coated cellulose reduces the fire risk of polyurethane foam biocomposites

Cellulose implementation as filler in polyurethane foams (PUF) often leads to an increased the fire risk associated to the prepared biocomposite. To address this problem, this paper presents a novel approach where the cellulose filler is coated by a nanostructured layer-by-layer (LbL) assembly with flame retardant characteristics before its addition to the biocomposite. During PUF production, the presence of cellulose led to a reduced cell size distribution with improved thermal insulation properties. By forced combustion tests, the use of neat cellulose produced a detrimental effect by increasing the PUF heat release rates (up to +21 %). Conversely, the coated cellulose simultaneously decreased the peak of heat release rate (-22 %) and the total smoke release (-32 %) if compared with the reference PUF. The proposed approach represents a viable strategy for the production of PUF biocomposites where sustainability and fire protection are optimized.