Thermally-protective intumescent coating system and method
First Claim
1. An intumescent coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising:
- (a) a first coating layer coated on the surface of said substrate and cured thereon to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; and
(b) a second coating layer coated on said first film layer and cured thereon to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam; and
wherein said intumescent coating system has a thickness of 1.27 mm (50 mils) or less.
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Abstract
An intumescent coating system and method therefor is disclosed for thermally protecting a substrate having a surface exposed to fire conditions. The coating system of the present invention is provided as having a having a first film layer which forms a rigid carbonific char foam having toughness and rigidity, and a second film layer which forms an insulative carbonific char foam having insulation properties. The two foam components may be separately provided in a laminate-type arrangement as, respectively, an inner coating layer coated and cured on the surface of the substrate to form an inner film layer, and an outer coating layer coated and cured on the inner film layer to form an outer film layer. In providing two foam components, one protecting the substrate from breakthrough and direct exposure to the fire conditions, and the other insulating the substrate to protect it from conductive, radiant, and/or convective heating by the fire conditions, the present invention affords a capability to offer flame retardancy at film thicknesses of 1.27 mm (50 mils) or less.
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Citations
18 Claims
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1. An intumescent coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising:
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(a) a first coating layer coated on the surface of said substrate and cured thereon to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; and (b) a second coating layer coated on said first film layer and cured thereon to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam; and
wherein said intumescent coating system has a thickness of 1.27 mm (50 mils) or less. - View Dependent Claims (2, 3, 4, 5, 6, 15, 16, 17)
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7. A method for thermally protecting a substrate having a surface exposed to fire conditions comprising the steps of:
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(a) coating said surface of said substrate with a first coating layer; (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; (c) coating a second coating layer on said first film layer; and (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam; and wherein said first and second film layers comprise an intumescent coating system having a thickness of 1.27 mm (50 mils) or less. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 18)
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Specification