Intumescent flame retardant polyurethane (IFRPU) composites were prepared in the presence of reduced graphene oxide (rGO) as synergism, melamine, and microencapsulated ammonium polyphosphate. The composites were examined in terms of thermal stability (both under nitrogen and air), electrical conductivity, gas barrier, flammability, mechanical, and rheological properties. Wide-angle X-ray scattering and scanning electron microscopy indicated that rGO are well-dispersed and exfoliated in the IFRPU composites. The limiting oxygen index values increased from 22.0 to 34.0 with the addition of 18wt% IFR along with 2wt% rGO. Moreover, the incorporation of rGO into IFRPU composites exhibited excellent antidripping properties as well as UL-94 V0 rating. The thermal stability of the composites enhanced. This was attributed to high surface area and good dispersion of rGO sheets induced by strong interactions between PU and rGO. The oxygen permeability, electrical, and viscoelasticity measurements, respectively, demonstrated that rGO lead to much more reduction in the gas permeability (by ~90%), high electrical conductivity, and higher storage modulus of IFRPU composites. The tensile strength, modulus, and shore A remarkably improved by the incorporation of 2.0wt% of rGO as well
