Intumescent composition and method

• US 6,228,914 B1
• Filed: 01/02/1998
• Issued: 05/08/2001
• Est. Priority Date: 01/02/1998
• Status: Expired due to Term

• Current Assignee: Georgia-Pacific Gypsum LLC (KOCH Industries Incorporated), NeoGraf Solutions, LLC, UCAR Graph-Tech Incorporated
• Original Assignee: Graftech, Incorporated, Georgia-Pacific Resins, Inc. (KOCH Industries Incorporated)
• Inventors: Garvey, Chad E., Ford, Brian M., Foucht, Mel E., Qureshi, Shahid P., Krassowski, Daniel W., Hutchings, David A.
• Primary Examiner(s): SANDERS, KRIELLION ANTIONETTE
• Application Number:
  US09/002,347
• Time in Patent Office: 1,222 Days
• Field of Search: 524/124, 524/429, 428/704, 252/609
• US Class Current: 524/124
• CPC Class Codes: C09D 5/185 Intumescent paints
• CPC Class Codes: C09K 21/12 containing phosphorus

Abstract

An aqueous composition containing a hardenable binder of a melamine compound, such as an acid-hardenable melamine-formaldehyde resin, and an acidic phosphorus compound, such as a nitrogen-containing phosphorus compound made from either phosphoric acid or phosphorus acid, and expandable graphite flake, which composition is curable to an intumescent composition.

Claims

1. An intumescent composition comprising a hardened binder of a melamine compound and an acidic phosphorus compound, said binder containing expandable graphite flakes.

5. The invention of claim 1, 2, 3 or 4 wherein the melamine compound is an acid curable melamine-formaldehyde resin.

6. The invention of claim 5 wherein the phosphorus compound contains one or more moieties of the following formula:

where R is selected from the group consisting of a C₁ to C₆ alkylene radical, a C₃ to C₇ cycloalkylene radical, an arylene radical and a divalent radical of the formula;

where x and z are integers of 1 to 6, and y is an integer from 0 to 2 and wherein the divalent radical is bonded to the phosphorous atom of said moieties through the terminal oxygen atom of said radical.

7. The invention of claim 1, 23 or 4 wherein the phosphorus compound is a compound of the following formula:

where R is selected from the group consisting of a C₁ to C₆ alkylene radical, a C₃ to C₇ cycloalkylene radical, an arylene radical and a divalent radical of the formula;

where x and z are integers of 1 to 6, and y is an integer from 0 to 2 and wherein the divalent radical is bonded to the phosphorous atoms of said compound through the terminal oxygen atom of said radical where i is 0 or 1, and R′

is selected from hydrogen, a C₁ to C₆ alkyl, a C₁ to C₆ alkoxy, a cycloalkyl and an aryl.

8. The invention of claim 7 wherein the melamine compound is a melamine-formaldehyde resin prepared by reacting melamine and formaldehyde in an aqueous reaction medium under an alkaline condition at a melamine to formaldehyde mole ratio in the range of 1:

1 to 6;

1.

9. The invention of claim 8 wherein the phosphorus compound is selected from the group consisting of aminotriethanol phosphate and aminotris(methylene-phosphonic acid).

10. The invention of claim 1, 23 or 4 wherein the phosphorus compound is a compound of the following formula (II):

where R is selected from the group consisting of a C₁ to C₆ alkylene radical, a C₃ to C₇ cycloalkylene radical, an arylene radical and a divalent radical of the formula;

were x and z are integers of 1 to 6, and y is an integer from 0 to 2 and wherein the divalent radical is bonded to the phosphorous atoms of said compound through the terminal oxygen atom of said radical and where R″

is a divalent organic radical.

11. The invention of claim 10 wherein the melamine compound is a melamine-formaldehyde resin prepared by reacting melamine and formaldehyde in an aqueous reaction medium under an alkaline condition at a melamine to formaldehyde mole ratio in the range of 1:

1 to 1;

6.

12. The invention of claim 11 wherein the phosphorus compound is ethylene diamine tetra(methylene phosphonic acid).

13. The invention of claim 1, 23 or 4 wherein the phosphorus compound is a compound of the following formula (III):

where R is selected from the group consisting of a C₁ to C₆ alkylene radical, a C₃ to C₇ cycloalkylene radical, an arylene radical and a divalent radical of the formula;

where x and z are integers of 1 to 6, and y is an integer from 0 to 2 and wherein the divalent radical is bonded to the phosphorous atoms of said compound through the terminal oxygen atom of said radical and where R″

is a divalent organic radical.

14. The invention of claim 13 wherein the melamine compound is a melamine-formaldehyde resin prepared by reacting melamine and formaldehyde in an aqueous reaction medium under an alkaline condition at a melamine to formaldehyde mole ratio in the range of 1:

1 to 1;

6.

15. The invention of claim 14 wherein the phosphorus compound is selected from the group consisting of diethylenetriaminepenta(methylene phosphonic acid) and bis hexamethylenetriaminepenta(methylene phosphonic acid).

16. The invention of claim 1, 23 or 4 wherein the phosphorus compound is a partial phosphate esters of phosphoric acid and a polyhydroxy compound.

17. The invention of claim 16 wherein the melamine compound is a melamine-formaldehyde resin prepared by reacting melamine and formaldehyde in an aqueous reaction medium under an alkaline condition at a melamine to formaldehyde mole ratio in the range of 1:

1 to 1;

6.

18. The invention of claim 17 wherein the phosphorus compound is the reaction product of phosphoric acid and a polyhydroxy compound selected from the group consisting of pentaerythritol, glycerol, trimethylol propane and mixtures thereof.

2. An aqueous composition suitable for producing a fire resistant coating on a substrate, said composition comprising a hardenable binder of a melamine compound and an acidic phosphorus compound, said binder containing expandable graphite flakes.

3. A method for imparting fire resistance to a substrate comprising treating said substrate with an aqueous composition comprising a hardenable binder of a melamine compound and an acidic phosphorus compound, said binder containing expandable graphite flakes.

4. A fire resistant article comprising a substrate coated or impregnated with a hardened aqueous composition, said composition comprising a hardenable binder of a melamine compound and an acidic phosphorus compound, said binder containing expandable graphite flakes.