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Multilayered coatings deposited using the layer-by-layer (LbL) assembly technique have attracted great interest in recent years as a sustainable and efficient solution for conferring flame retardant properties to fabrics. The unique structure and interaction established upon the coating assembly are the key factors for successful flame retardant properties. In this study we aimed at the deposition of multilayered coatings comprising chitosan and montmorillonite with a LbL-like structure and interactions by the simple processing of compacted chitosan/montmorillonite complexes obtained by the direct mixing of an oppositely charged solution/suspension. Upon drying, the prepared complex yielded a continuous coating characterized by a brick-and-mortar multi-layered structure, in which oriented clay nanoplatelets were held together by a continuous chitosan matrix. When deposited on acrylic fabrics these coatings were able to suppress the melt-dripping phenomenon, and at 10 and 20% add-ons achieved self-extinguishing behavior within a few seconds after ignition. Cone calorimetry testing revealed an increase in time to ignition (up to +46%) and considerable reductions of the rates at which heat is released (up to −62 and −49% for peak of heat release rate and total heat release, respectively). A reduction in the total smoke release (up to −49%) was also observed.

Flame Retardant Multilayered Coatings on Acrylic Fabrics Prepared by One-Step Deposition of Chitosan/Montmorillonite Complexes