Intumescent Coating Composition

• US 20150291810A1
• Filed: 11/25/2013
• Published: 10/15/2015
• Est. Priority Date: 11/23/2012
• Status: Active Grant

• Current Assignee: PPG Coatings Europe B.V (Nouryon BV)
• Original Assignee: PPG Coatings Europe B.V (Nouryon BV)
• Inventors: Peskens, Ronnie
• Granted Patent: US 10,072,163 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C09D 5/185 Intumescent paints
• CPC Class Codes: C09K 21/10 containing nitrogen
• CPC Class Codes: C09K 21/14 Macromolecular materials

Abstract

An intumescent coating composition and a coated metal substrate are described. The composition comprises: (a) a polymeric binder; (b) an acid catalyst effective to form a polyphosphoric acid on thermal decomposition; (c) a solid carbon donor; (d) a liquid carbon donor in the form of one or more polyhydric alcohols effective to form a phosphoric acid ester on contact with phosphoric acid; (e) an expansion agent; (f) one or more pigments; (g) optionally, one or more other additives; (h) a liquid carrier for the polymeric binder The ratio of combined components (b), (c), (e) and (f):(a) is at least 4:1 w/w. A coating composition wherein the concentration of components (b), (e) and (f) is in the range 55-75% w/w solids is further described.

Claims

1. An intumescent coating composition comprising:

—

(a) a polymeric binder;

(b) an acid catalyst effective to form a phosphoric acid;

(c) a solid carbon donor;

(d) a liquid carbon donor in the form of one or more polyhydric alcohols effective to form a phosphoric acid ester on contact with phosphoric acid wherein the phosphoric acid ester has a lower temperature of decomposition than the equivalent pentaerythritol phosphoric acid ester;

(e) an expansion agent;

(f) one or more pigments;

(g) optionally, one or more other additives;

(h) a liquid carrier fir the polymeric, binder wherein the liquid carrier may be water or an organic solvent and when the liquid carrier is water the binder and liquid carrier are in the form of an aqueous polymeric dispersion; and

wherein the ratio of combined components (b), (c), (e) and (f);

(a) is at least 4;

1 w/w.

5. An intumescent coating composition or coating according to claim 1, wherein the ratio of combined components (b), (c), (e) and (f):

(a) is from 4;

1 to 8;

1 w/w.

6. An intumescent coating composition or coating according to claim 1, wherein the ratio of (b):

(c) is at least 3;

1 w/w.

7. An intumescent coating composition or coating according to claim 1, wherein the ratio of (e):

(c) is at least 3;

2 w/w.

8. An intumescent coating composition or coating according to claim 1, wherein the ratio of (f):

(c) is at least 2;

1 w/w.

9. An intumescent coating composition or coating according to claim 1, wherein the ratio of (b):

(d) is at least 6;

1 w/w.

10. An intumescent coating composition or coating according to claim 1, wherein the ratio of (e) (d) is at least 3:

2 w/w.

11. An intumescent coating composition or coating according to claim 1, wherein the ratio of (f):

(d) is at least 2;

1 w/w.

16. An intumescent coating composition or coating according to claim 1, wherein the polymeric binder is vinyl acetate based.

17. An intumescent coating composition or coating according to claim 16, wherein the polymeric binder is selected from a vinyl acetate-ethylene copolymer or a vinyl acetate-VeoVa copolymer.

20. An intumescent coating composition or coating according to claim 1, wherein the liquid carrier comprises xylene or a toluene-methylketone blend.

21. An intumescent coating composition according to claim 1, wherein the hinder is present at 5-40% w/w solids.

22. An intumescent coating composition or coating according to claim 1, wherein the solid carbon donor is an organic polyhydroxy compound.

23. An intumescent coating composition or coating according to claim 22, wherein the solid carbon donor is selected from pentaerythritol, dipentaerythritol, tripentaerythritol, starch or sugars.

24. An intumescent coating composition or coating according to claim 23, wherein the solid carbon donor is pentaerythritol.

25. An intumescent coating composition according to claim 1, wherein the expansion agent decomposes/is activated in the range 280 to 390°

C.

26. An intumescent coating composition according to claim 1, wherein the expansion agent is a nitrogen containing compound.

27. An intumescent coating composition according to claim 26, wherein the expansion agent is selected from melamine, melamine salts, melamine derivatives, urea, dicyandiarnide and guanidine.

28. An intumescent coating composition according to claim 27, wherein the expansion agent is melamine.

29. An intumescent coating composition according to claim 1, wherein the acid catalyst (b) is selected from phosphoric esters of polyhydroxy compounds, ammonium phosphates or amine phosphates.

30. An intumescent coating composition or coating according claim 29, wherein the acid catalyst (b) is ammonium polyphosphate (APP).

33. A method of fire protecting a substrate, comprising applying an intumescent coating composition according to claim 1 to at least a portion of the substrate.

2. An intumescent coating composition comprising:

—

(a) a polymeric binder;

(b) an acid catalyst effective to form a phosphoric acid;

(c) a solid carbon donor;

(d) a liquid carbon donor in the form of one or more polyhydric alcohols effective to form a phosphoric acid ester on contact with phosphoric acid wherein the phosphoric acid ester has a lower temperature of decomposition than the equivalent pentaerythritol phosphoric acid ester;

(e) an expansion agent;

(f) one or more pigments;

(g) optionally, one or more other additives;

(h) a liquid carrier for the polymeric binder wherein the liquid carrier may be water or an organic solvent and when the liquid carrier is water the binder and liquid carrier are in the form of an aqueous polymeric dispersion; and

wherein the concentration of components (b), (e) and (f) in the coating composition is in the range 55-75% w/w solids.

12. An intumescent coating composition or coating according to claim 2, wherein the solid carbon donor (c) is present in the coating composition in the range 10-80% w/w total carbon donor.

3. A dry coating composition coated onto a surface comprising:

—

(a) a polymeric binder derived from either an aqueous polymeric dispersion of the binder or an organic solvent based solution of the binder;

(b) an acid catalyst effective to form a phosphoric acid;

(c) a solid carbon donor;

(d) a liquid carbon donor in the form of one or more polyhydric alcohols effective to form a phosphoric acid ester on contact with phosphoric acid wherein the phosphoric acid ester has a lower temperature of decomposition than the equivalent pentaerythritol phosphoric acid ester;

(e) an expansion agent;

(f) one or more pigments; and

(g) optionally, one or more other additives;

wherein the ratio of combined components (b), (c), (e) and (f);

(a) is at least 4;

1 w/w.

13. An intumescent coating composition or coating according to claim 3, wherein the liquid carbon donor (d) is present in the coating composition in the range 90 to 20% w/w total carbon donor (c) and (d).

15. An intumescent coating composition or coating according to claim 3, wherein the liquid carbon donor is glycerine.

4. A coated metal substrate wherein the coating comprises:

—

(a) a polymeric binder;

(b) an acid catalyst effective to form a phosphoric acid;

(c) a solid carbon donor;

(d) a liquid carbon donor in the form of one or more polyhydric alcohols effective to form a phosphoric acid ester on contact with phosphoric acid wherein the phosphoric acid ester has a lower temperature of decomposition than the equivalent pentaerythritol phosphoric acid ester;

(e) an expansion agent;

(f) one or more pigments;

(g) optionally, one or more other additives;

wherein the ratio of combined components (b), (c), (e) and (f);

(a) is at least 4;

1 w/w.

19. A coated metal substrate according to claim 4, wherein the polymeric binder is derived from either an aqueous polymeric dispersion of the binder or an organic solvent based solution of the binder.

14. (canceled)

18. (canceled)

31-32. -32. (canceled)

34. (canceled)