Fast curing intumescent coating

Abstract

The present disclosure provides an intumescent coating composition comprising: (a) a molecule comprising one or more acyl acyloxy groups; (b) an epoxy resin; (c) a molecule comprising a ketimine and / or aldimine group; and (d) a swelling agent. The intumescent coating composition may have a surface dry time (ASTM-D1640-2014) of less than 200 minutes at 23 DEG C and 40% relative humidity.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 513,698, filed July 14, 2023, which is filed under 35 U.S.C 119, entitled “Fast-Cured Intumescent Coatings”; which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present disclosure relates generally to intumescent coating compositions and methods of making and using the same. BACKGROUND

[0003] It is desirable to have intumescent coating compositions with faster dry times. SUMMARY

[0004] The present disclosure relates to intumescent coating compositions comprising: (a) a molecule comprising one or more acyl acyloxy groups; (b) an epoxy resin; (c) a molecule comprising a ketimine group; and (d) an intumescent agent. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1 Potential reaction mechanisms for some of the intumescent coatings described herein are shown. DETAILED DESCRIPTION

[0006] For purposes of the following detailed description, it is to be understood that the disclosure can assume various alternative arrangements and step sequences, except where expressly indicated to the contrary, and all such changes and modifications are intended to be included within the scope of the disclosure. Also, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting, unless explicitly so defined herein. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Unless otherwise expressly defined herein, all

[0007] Notwithstanding that the numerical ranges and parameters setting forth the broadest scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0008] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges of the recited minimum and maximum values. For example, a range of 1 to 10 is intended to include all sub-ranges, for example, 1 to 6.1, 5.1 to 10, 1.1 to 1.4, etc., as well as 1 to 10.

[0009] In this application, the use of singular terms includes the plural and the use of plural terms includes the singular, unless specifically stated otherwise. Additionally, in this application, the use of "or" means "and / or" unless specifically stated otherwise, even though "and / or" can be explicitly used in certain instances. Further, in this application, the use of "a" or "an" means "one or more" unless specifically stated otherwise. For example, "a" polymer, "an" acid, etc., means one or more of these items.

[0010] Unless otherwise indicated, ambient conditions for temperature and pressure are ambient temperature (20-25 °C) and standard pressure of 101.3 kPa (1 atm).

[0011] The present disclosure relates to an intumescent coating composition comprising: (a) a molecule comprising one or more acyl acyloxy (ACAC) groups (such as acetoacetoxy groups); (b) an epoxy resin; (c) a molecule comprising ketimine and / or aldimine groups; and (d) an intumescent agent.

[0012] The intumescent coating composition of the present invention is rapidly cured and comprises a polyacyl acyloxy (ACAC)-ketimine / aldimine-epoxy resin based adhesive and an intumescent agent. The intumescent coating composition of the present invention can be rapidly cured / dried to be handled within 2 hours at 23 °C. The intumescent fireproof coating composition of the present invention is suitable for fireproofing as a coating for metal substrates and / or non-metal substrates (as non-limiting examples, steel parts such as column, beam or truss members) to increase the fire resistance time.

[0013] The intumescent coating composition of the present invention can be substantially free (less than 1 wt%), essentially free (less than 0.1 wt%) or completely free (not detectable) of a separate gas source. For example, melamine or melamine-containing compounds can be excluded or not included in the intumescent coating composition.

[0014] Molecule comprising one or more ACAC groups

[0015] The intumescent coating composition of the present invention comprises a molecule comprising one or more acyl acyloxy (ACAC) groups. The ACAC group can be a terminal group on the molecule. The ACAC group can conform to the following formula:

[0016]

[0017] wherein R 1 is a difunctional C1-C4 alkyl radical, such as methylene, and R 2 is a C1-C4 alkyl radical, such as methyl. When R 1 and R 2 are C1, the ACAC group is an acetoacetoxy group.

[0018] Molecules comprising one or more ACAC groups can be oligomers or polymers. A non-limiting example of a polymer comprising one or more ACAC groups is a polymer wherein R 1 is CH2, R 2 is methyl, and the ester groups are provided as pendent to the main chain of the oligomer or polymer. The acyl acyloxy functionality can be terminal, branched, or pendent or mixtures thereof. As a non-limiting example, at least one branch of the oligomer or polymer terminates with an acyl acyloxy functionality. The acyl acyloxy functionality can be bonded to a polyester functional block or directly to a polyol functional block, as required by the specific application.

[0019] Derivatives of the above ACAC containing oligomers or polymers can include, but are not limited to, (a) polypropylene based (e.g., co-reacted with polypropylene glycol), polyglycol based (e.g., co-reacted with polycarbonate diols, polypropylene glycol, polyether glycols, polyester glycols, etc.), (b) urethane backbones and / or urethane modified (e.g., co-reacted with isocyanates) repeats thereof, (c) silicones, silanes, (meth)acrylates, acrylics, but are not limited thereto. Such molecules comprising one or more ACAC groups can be used alone or in admixture with an epoxy resin adhesive as described herein.

[0020] As a non-limiting example, the ACAC containing oligomer or polymer can include an acetoacetate functional dimer fatty acid based polyol / polyester block copolymer, such as an AcAc functional polymer initially formed from caprolactone.

[0021] The ACAC-containing oligomer or polymer can be a flexible block copolymer. As a non-limiting example, the flexible block copolymer may contain at least one hydrophobic polyol block; a functional cap provided by an epoxy group, an acetoacetate group, or both. As a non-limiting example, the cap may have a functionality greater than 1. The oligomer or polymer may also contain optional functional extension groups, such as isocyanates or silicones, to obtain flexibility. To provide flexibility, the block copolymer may, but is not limited to, include selected polyalkylene glycol diol blocks with a molecular weight that imparts flexibility, or if the hydrophobic polyol block includes an epoxy group and / or a fatty acid-derived polyol group, the flexible copolymer may also include one or more lactone-derived flexible blocks, each block having at least three or more repeating lactone group residues. Optional functional groups may include hydroxyl groups and other groups that do not produce adverse reactions / conditions with the remaining components in the intumescent coating composition.

[0022] Molecules containing one or more ACAC groups may have a molecular weight of less than 5,000 g / mol, such as less than 3,000 g / mol, less than 1,500 g / mol, less than 1,250 g / mol, or less than 1,000 g / mol, and may be between 300 and 5,000 g / mol, such as 500 to 3,000 g / mol, 350 to 1,500 g / mol, or 500 to 1,000 g / mol.

[0023] Molecules containing one or more ACAC groups that can be used in the intumescent coating compositions of the present invention can be prepared by reacting 1,4-cyclohexanedicarboxylic acid, isophthalic acid, ethylene glycol, 2,2-dimethyl-1,3-propanediol, 1,4-cyclohexanediol, trimethylolpropane, and tert-butyl acetoacetate in the presence of butylstannic acid and triphenyl phosphite as catalysts. The resulting product may contain one or more compounds according to the following formula:

[0024]

[0025] Molecules containing one or more ACAC groups may be present in the intumescent coating composition in an amount of at least 5% by weight, such as at least 10% by weight, at least 15% by weight, or at least 20% by weight, based on the total weight of the intumescent coating composition, and may be present in an amount of up to 30% by weight, such as up to 20% by weight, or up to 10% by weight, based on the total weight of the intumescent coating composition. Molecules containing one or more acyl oxy groups may be present in the intumescent coating composition in an amount ranging from 5% to 30% by weight, 5% to 25% by weight, 5% to 20% by weight, 10% to 30% by weight, 10% to 25% by weight, 15% to 30% by weight, 15% to 20% by weight, 20% to 30% by weight, 20% to 25% by weight, or 25% to 30% by weight, based on the total weight of the intumescent coating composition.

[0026] Epoxy resin

[0027] The epoxy resin (b) in the intumescent coating composition may contain the reaction product of a polyhydroxy compound such as a polyvalent phenol or a phenol-aldehyde condensate with an epihaloalcohol or its precursor.

[0028] The epoxy resin can be a polyepoxide resin. As a non-limiting example, it can be a polyepoxide resin containing at least two ethylene oxide groups in its molecule, i.e.,

[0029]

[0030] Where n is at least two, R3 is hydrogen or methyl, and R4 broadly represents an organic-based molecule or polymer typically composed of carbon, hydrogen, oxygen, and optionally nitrogen and / or sulfur. Hydroxyl substituents, as well as halogen and ether groups, may also be present and are frequently present. Typically, the epoxide equivalent ranges from about 60 to about 1000, such as from about 100 to about 500 or from about 150 to about 250. These resins can be broadly classified as aliphatic, aromatic, cyclic, acyclic, cycloaliphatic, or heterocyclic.

[0031] Polyepoxide resins that may be used herein include, but are not limited to, epoxy phenolic resins. These resins can be prepared by reacting epichlorohydrin with aldehydes and mono- or poly-phenolic condensation products. Non-limiting examples include reaction products of epichlorohydrin with phenolic condensates.

[0032] Another group of useful polyepoxide resins includes, but is not limited to, polyglycidyl ethers of polyhydric aromatic alcohols, such as, for example, diphenols. The phenol may be at least dihydroxy. Suitable non-limiting examples include resorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-1,1-isobutane; 4,4-dihydroxybenzophenone; bis(4-hydroxyphenyl)-1,1-isobutane; bis(4-hydroxyphenyl)-1,1-ethane; bis(2-hydroxynaphthylphenyl)methane; 1,5-hydroxynaphthalene; and 4,4'-isopropylidene diphenol (i.e., bisphenol A), which can be utilized. Epichlorohydrin can be used, although epibromohydrin can also be used. Polyglycidyl ethers suitable for use herein can be obtained by reacting epichlorohydrin and bisphenol A in the presence of a base such as sodium hydroxide or potassium hydroxide. The EPON series of epoxy resins sold by Hexion can be used herein.

[0033] Another group of useful polyepoxide resins includes, but is not limited to, polyglycidyl ethers derived from polyols such as ethylene glycol; diethylene glycol; triethylene glycol; 1,2-propanediol; 1,4-butanediol; 1,5-pentanediol; 1,2,6-hexanetriol; glycerol; and trimethylolpropane.

[0034] Also useful, but not limited to, in this article are polyepoxide resins of polyglycidyl ethers as polycarboxylic acids. These materials are produced by the reaction of epoxy compounds such as epichlorohydrin with aliphatic or aromatic polycarboxylic acids such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid, and dimer linoleic acid.

[0035] Another group of polyepoxide resins that can be used includes, but is not limited to, those epoxidized polyepoxide resins derived from olefinic unsaturated cyclic aliphatic materials. Among these are epoxy cyclic aliphatic ethers and esters well known in the art.

[0036] In addition to the materials discussed above and the structures of polymers containing ethylene oxide groups mentioned above, useful epoxy resins may also include, but are not limited to, those containing alkylene oxide groups, i.e., R... 3 The group is hydrogen or a C1 to C6 alkyl group, where m is an integer from 1 to 4 and n is an integer from 2 to 50. Such groups can be side chains of the main chain of the epoxide resin, or they can be included as part of the main chain. The proportion of olefinic groups in a polyepoxide resin depends on several factors, including the size of the olefinic groups and the properties of the epoxy resin. Mixtures of polyepoxide resins are also useful herein.

[0037] Epoxy resins may include, but are not limited to, one or more of the following:

[0038] a) The reaction products of epichlorohydrin with bisphenol A, F or S;

[0039] b) The reaction product of epichlorohydrin and bisphenol S;

[0040] c) Epoxy phenolic resins based on phenol or cresol;

[0041] d) Aromatic glycidyl amine resins;

[0042] e) Epoxy resins that do not have aromatic structural units;

[0043] f) Aliphatic or cycloaliphatic polyepoxides;

[0044] and their combinations or mixtures.

[0045] Epoxy resins can have an epoxide equivalent weight in the range of 60 to 1000, such as 100 to 500, or 150 to 250 molar epoxy groups per 100g of resin.

[0046] Based on the total weight of the intumescent coating composition, epoxy resin may be present in the intumescent coating composition in an amount of at least 3% by weight, such as at least 5% by weight or at least 7% by weight, and may be present in an amount of up to 9.9% by weight, such as up to 9.2% by weight or up to 8.5% by weight. Epoxy resin may be present in the intumescent coating composition in an amount ranging from 3 to 9.9% by weight, such as 3 to 9.2% by weight, 3 to 8.5% by weight, 5 to 9.9% by weight, 5 to 9.2% by weight, 5 to 8.5% by weight, 7 to 9.9% by weight, 7 to 9.2% by weight or 7 to 8.5% by weight.

[0047] Molecules containing ketimine and / or aldehyde imine groups

[0048] Molecules containing ketimine groups can be, but are not limited to, ketimine-containing polyepoxides and / or aliphatic ketimines. Ketoimine-containing polyepoxides can be prepared as known in the art by modifying a polyamine with a ketone, followed by reacting the remaining nucleophilic group with the polyepoxide. Aliphatic ketimines can be prepared as known in the art by reacting an aliphatic diamine with an aliphatic ketone. The polyepoxide in the ketimine-containing polyepoxide can be the same as or different from the epoxy resin (b) in the intumescent coating composition.

[0049] Molecules containing ketimine groups can be reaction products of polyamines and ketone-containing molecules.

[0050] A molecule containing a ketimine group can be the product of a reaction between a polyamine and a ketone-containing molecule to form a polyamine / ketone product, which is then reacted with an epoxide-containing molecule to form a molecule containing a ketimine group.

[0051] The polyepoxide resin used to prepare the ketimine-containing polyepoxide resin can be selected from various materials, such as the epoxy resin mentioned above.

[0052] Epoxide-containing molecules may include epoxy resins having an epoxide equivalent weight in the range of 60 to 1000, such as 100 to 500 or 150 to 250 molar epoxy groups per 100g of resin.

[0053] The molecule including the ketimine group can be a ketimine-containing polyepoxide, which can be prepared from any of the aforementioned polyepoxides in the following manner. First, a polyamine compound having an average of at least two amine groups per molecule, such as a polyamine modified by reacting with a ketone to form a ketimine. As a non-limiting example, one mole of diethylenetriamine can be reacted with two moles of methyl isobutyl ketone to produce a diketimine with secondary amine functionality plus two moles of water. As another non-limiting example, an aldehyde can be used instead of or in combination with a ketone to form a modified amine called an aldehydeimine. The resulting ketimine or aldehydeimine-modified amine is then reacted with the polyepoxide to effectively deplete all the ethylene oxide groups of the polyepoxide and produce a ketimine or aldehydeimine containing a polyepoxide unit, which may be substantially free of ethylene oxide groups. "Substantially free of ethylene oxide groups" means that the epoxy equivalent weight of the polyepoxide containing ketimine and / or aldehyde imine is measured to be at least about 5000 (g / equivalent epoxy). In other words, the polyepoxide containing ketimine and / or aldehyde imine is calculated to contain less than 1, such as less than 0.5, ethylene oxide groups per molecule on average.

[0054] Representative polyamines that can be used in the practice of this disclosure can be described as having 2 to 10 primary and / or secondary amino groups, such as 2 to 4 primary amino groups and 2 to 200 carbon atoms, and are aliphatic or cycloaliphatic amines. Examples of suitable polyamines include, but are not limited to, ethylenediamine, propylenediamine, butanediamine, pentanediamine, hexanediamine, decanediamine, 4,7-dioxadecane-1,10-diamine, dodecanediamine, 4,9-dioxadecane-1,12-diamine, 7-methyl-4,10-dioxadecane-1,13-diamine, 1,2-diaminocyclohexane, 1,4-diaminocyclohexane, and 4,4'-diaminocyclohexane. Cyclohexylmethane, isophorone diamine, bis(3-methyl-4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, tri(ethylamine) nitrile, bis(3-aminopropyl)methylamine, 2-amino-1-(methylamino)propane, 3-amino-1-(cyclohexylamino)propane, N-(2-hydroxyethyl)ethylenediamine, isophorone diamine, 1,2-diaminopropane, 1,3-diaminopropane Alkane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,8-diaminooctane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4-trimethyl-1,6-diaminohexane, 2,4,4-trimethyl-1,6-diaminohexane, 1,11-diaminoundecane, 1,12-diaminodecane Diane, 1,3-cyclohexanediamine, 1,4-cyclohexanediamine, 1-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4'-diamino-dicyclohexylmethane, 4,4'-diamino-dicyclohexylmethane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane and / or 3,3'-diethyl-4,4'-diamino-dicyclohexylmethane and combinations thereof.

[0055] A group of polyamines used in this disclosure can be represented by the following structural formulas:

[0056] H2N —(R 5 —NH) n —R 6 —NH2

[0057] Among them, group R 5 and R 6 These can be the same or different, and represent alkylene groups containing 2 to 6 carbon atoms (such as 2 to 4 carbon atoms), and n is a number from 1 to 6 (such as 1 to 3). An alkylene group means a cycloalkylene group, an alkylene group, or an alkylene group containing an ether-oxygen atom. Representative examples of polyalkylene polyamines include diethylenetriamine, dipropylenetriamine, and dibutyltriamine. These polyamines have two primary amino groups and one secondary amino group.

[0058] Ketones used to modify polyamines can be represented by the following structural formula:

[0059]

[0060] Where R and R' are independently alkanes having between 1 and 12 carbon atoms. Aldehydes according to the structure RC(O)H can also be used, where R is as defined above.

[0061] Examples of suitable ketones and aldehydes used as modifiers or sealing agents for the amine groups of this disclosure include, but are not limited to, acetone, diethyl ketone, methyl isobutyl ketone, isobutyraldehyde, hydroxybutyraldehyde, pentanone, cyclohexanone, ethylpentyl ketone, hydroxycitronellol, isophorone, and decanone.

[0062] Aliphatic ketone imines and / or aldehyde imines can be prepared as known in the art by reacting an aliphatic diamine with an aliphatic ketone or an aliphatic aldehyde. Suitable examples of diamines include, but are not limited to: isophorone diamine, ethylenediamine, 1,2-diaminopropane, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,8-diaminooctane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4-trimethyl-1,6-diaminohexane, and 1,11-diamino... Undecane, 1,12-diaminododecane, 1,3-cyclohexanediamine, 1,4-cyclohexanediamine, 1-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4'-diamino-dicyclohexylmethane, 4,4'-diamino-dicyclohexylmethane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane, and / or 3,3'-diethyl-4,4'-diamino-dicyclohexylmethane. Suitable ketones include, but are not limited to, acetone, methyl ethyl ketone, methyl isobutyl ketone, and / or methyl pentyl ketone. Suitable aldehydes include, but are not limited to, isobutyraldehyde, hydroxybutyraldehyde, and hydroxycitronellol. As a non-limiting example, aliphatic ketimines can be prepared from a reaction mixture comprising isophoronediamine and methyl isobutyl ketone.

[0063] Polyketimide and / or aldehydeimide resins may have a weight-average molecular weight of 300 to 10,000 g / mol, such as about 500 to about 5,000 g / mol or about 600 to about 1200 g / mol, as determined by gel permeation chromatography (GPC) using polystyrene standards. Further, polyepoxide resins containing ketimides and / or aldehydeimides can be described as having an average of at least two ketimide and / or aldehydeimide groups per molecule, such as an average of about 2 to about 25 ketimide and / or aldehydeimide groups per molecule, or about 3 to about 6 ketimide and / or aldehydeimide groups per molecule.

[0064] Based on the total weight of the coating composition, molecules containing ketimide and / or aldehyde groups are present in the present invention in an amount of at least 10% by weight, such as at least 20% by weight, at least 25% by weight, or at least 30% by weight. Based on the total weight of the composition, polyketimide and / or aldehyde may be present in the present invention in an amount of up to 40% by weight, such as up to 30% by weight or up to 20% by weight. Therefore, polyketimide and / or aldehyde may be present in the intumescent coating composition in an amount ranging from 10% to 40% by weight, such as 10% to 30% by weight, or 10% to 20% by weight, or 15% to 40% by weight, or 10% to 30% by weight, or 15% to 20% by weight, or 20% to 40% by weight, or 20% to 30% by weight, or 25% to 40% by weight, or 25% to 30% by weight.

[0065] Expanding agent

[0066] The expanding agent used in an intumescent coating composition may include one or more of a gas source, a carbon source, an acid source, reinforcing fibers, other inorganic additives, and combinations thereof. The total amount of the expanding agent may be 5 to 55% by weight, such as 6 to 50% by weight, based on the total weight of the intumescent coating composition.

[0067] As described above, intumescent coating compositions may be substantially free of (less than 1% by weight), substantially free of (less than 0.1% by weight), or completely free of (undetectable) independent gas sources. For example, melamine or melamine-containing compounds may be excluded or not included in the intumescent coating composition. As used herein, the term "independent gas source" refers to one or more molecules in the intumescent coating composition that act as foaming agents by degrading and releasing flammable gases, which can cause the layers of the intumescent coating composition to expand, resulting in the formation of a swollen porous layer.

[0068] Common gas sources are nitrogen-containing, including ammonium polyphosphate, azodicarbonamide, p-toluenesulfonamide, 4,4'-oxobis(benzenesulfonylhydrazine), dinitrosopentamethylenetetramine, p-toluenesulfonamide, 5-phenyltetrazole, diazobenzenesulfonate, melamine and melamine derivatives, as well as urea or urea derivatives.

[0069] When the expanding agent includes melamine and / or melamine derivatives, the expanding agent may include salts of melamine, melamine-formaldehyde, hydroxymethylated melamine, hexamethoxymethylmelamine, melamine monophosphate, bis(melamine phosphate), melamine dihydrogen phosphate, melamine (-2,5,8-triamino-1,3,4,6,7,9,9b-heptazophenanthrene), melamine (poly[8-amino-1,3,4,6,7,9,9b-heptazophenanthrene-2,5-diyl)imino), and melamine (1,3,5-triazine-2,4,6-triamine-n-(4,6-diamino-1,3,5-triazine-2-yl) and mixtures or combinations thereof.

[0070] Additional gas sources include, but are not limited to: diisocyanate-(hydroxyethyl)isocyanurate (THEIC), boric acid, trichloroethyl phosphate (TCEP), trichloropropyl phosphate (TCPP), or chlorinated paraffin. The resin itself can also act as a gas source through decomposition. Melamine can be a gas source.

[0071] When the expanding agent contains a gas source, the expanding coating composition may contain boron-containing compounds, such as boric acid, and borates, such as ammonium pentaborate, zinc borate, sodium borate, lithium borate, aluminum borate, magnesium borate, and borosilicates, as well as mixtures or combinations thereof.

[0072] When the expanding agent contains a carbon source, the carbon source may contain tall oil fatty acids and / or an aromatic compound containing at least one aromatic ring, such as 2, 3, or 4 aromatic rings, such as a benzene ring, a naphthalene ring, anthracene ring, or a phenanthrene ring, and wherein the aromatic compound may optionally contain at least one functional substituent, such as a hydroxyl, carboxyl, mercapto, and / or amino group. As a non-limiting example, the aromatic compound may include one or more of bisphenol A, bisphenol B, and bisphenol F. As a non-limiting example, the aromatic compound may include an aromatic compound having a long-chain hydrocarbon substituent, such as a saturated or unsaturated hydrocarbon group having a straight-chain or branched alkyl and / or alkenyl and / or alkynyl group having 6 to 20 carbon atoms, such as 6 to 18 carbon atoms or 6 to 15 carbon atoms; wherein the long-chain hydrocarbon group optionally contains 1 to 3 unsaturated bonds, such as double bonds and / or alkynyl bonds.

[0073] Many types of compounds can be used as carbon sources or carbonizing agents, including pentaerythritol (monomers, dimers, and trimers), sorbitol, mannitol, dextrin, starch, phenol-formaldehyde resins, and carbonized polymers such as nylon 6, polyurethane, and polycarbonate.

[0074] When the expanding agent includes a carbon source, the carbon source may be present in the expanding coating composition in the range of 0.5 to 50% by weight, such as in the range of 10 to 18% by weight, in the range of 11 to 17% by weight, or in the range of 12 to 16% by weight, based on the total weight of the expanding coating composition.

[0075] When the expanding agent contains an acid source, the acid source may contain one or more of the following: phosphates, such as phosphoric acid, sodium phosphate, potassium phosphate or ammonium phosphate, ammonium polyphosphate (APP), monoammonium phosphate, diammonium phosphate, trichloroethyl phosphate (TCEP), trichloropropyl phosphate (TCPP), ammonium pyrophosphate and triphenyl phosphate; sulfonates, such as sulfonic acid, sodium sulfonate, potassium sulfonate, ammonium sulfonate and p-toluenesulfonate; and sulfates, such as sodium sulfate, potassium sulfate and ammonium sulfate.

[0076] When the expanding agent contains an acid source, the acid source may be present in the expanding coating composition in an amount ranging from 5 to 30% by weight, such as from 5 to 25% by weight, from 5 to 20% by weight, or from 5 to 15% by weight, based on the total weight of the expanding coating composition.

[0077] When the expanding agent contains reinforcing fibers, the reinforcing fibers may include one or both of inorganic and organic fibers. Inorganic fibers may include one or more of the following: carbide fibers, such as boron carbide fibers, silicon carbide fibers, and niobium carbide fibers; nitride fibers, such as silicon nitride fibers; boron-containing fibers, such as boron fibers and boride fibers; silicon-containing fibers, such as silicon fibers, alumina-boron-silica fibers, alkali-free aluminum borate fibers, alkali-free or low-alkali sodium-calcium-aluminum borosilicate fibers, alkali sodium-calcium-silicate fibers, S-glass fibers, inorganic glass fibers, quartz fibers; ceramic fibers; basalt fibers, and combinations thereof.

[0078] When the expanding agent contains reinforcing fibers, the reinforcing fibers may be present in the expanding coating composition in the range of 0 to 5% by weight, such as in the range of 1 to 4% by weight or in the range of 2 to 5% by weight, based on the total weight of the expanding coating composition.

[0079] When the expander contains other inorganic additives to enhance its flame retardant properties, the other inorganic additives may include one or more of the following: titanium dioxide (TiO2); aluminum hydroxide; expandable graphite and combinations thereof.

[0080] When the expanding agent contains inorganic additives, the inorganic additives may be present in the expanding coating composition in an amount ranging from 0 to 50% by weight, such as in the range of 15 to 40% by weight, in the range of 15 to 35% by weight, in the range of 15 to 30% by weight, or in the range of 15 to 25% by weight, based on the total weight of the expanding coating composition.

[0081] Apply the intumescent coating composition to the substrate.

[0082] Not bound by any particular theory, and as such Figure 1 The non-limiting example shown illustrates that when the intumescent coating composition of this disclosure is applied to at least a portion of a substrate and exposed to ambient moisture, the ketimine and / or aldolimine components decompose (i.e., deblock) to produce a primary amine, which rapidly reacts with (ACAC) groups to form an imine. The final product is an enamine, which is formed by the tautomerism of the imine over time and is thermodynamically favorable. Although rapid crosslinking of the ketimine and / or aldolimine with acyloxy groups readily occurs, the enamine is reversible in the presence of water and can be converted back to the primary amine and acyloxy groups. The extent of this reaction is determined by equilibrium, and the rate is determined by the pH of the intumescent coating composition and the presence or absence of other catalysts (e.g., ionic substances). A secondary crosslinking reaction can be incorporated by adding a polyepoxide resin. This is believed to form irreversible bonds through reaction with the enamine product and the primary and tertiary amine components of the adhesive.

[0083] The intumescent coating compositions according to this disclosure can have a surface drying time of less than or equal to 200 minutes at 23°C and 40% relative humidity, such as less than or equal to 175 minutes, less than or equal to 150 minutes, or less than or equal to 125 minutes (ASTM-D1640-2014), and the surface drying time can be in the range of 50 to 200 minutes, such as in the range of 60 to 175 minutes, in the range of 70 to 150 minutes, or in the range of 50 to 125 minutes. The surface drying time can be obtained without including a catalyst in the intumescent coating compositions described herein.

[0084] The intumescent coating compositions disclosed herein can be applied to any suitable substrate. Such substrates include, but are not limited to, concrete, wood, plastics, fiberglass, and rigid metal substrates such as one or more of ferrous metals, aluminum, aluminum alloys, and copper. Ferrous metals may include one or more of the following: cold-rolled steel, galvanized (zinc-coated) steel, electro-galvanized steel, stainless steel, pickled steel, zinc-iron alloys, and combinations or composites of ferrous and non-ferrous metals. The intumescent coating compositions can be applied by methods selected from brushing, flow coating, and spraying.

[0085] The intumescent coating composition according to this disclosure can be applied by optionally cleaning and / or degreasing at least a portion of the surface of a substrate, followed by applying the intumescent coating composition as described above.

[0086] Intumescent coating compositions can be single-component or multi-component compositions. When an intumescent coating composition is a multi-component composition, it may comprise a first component and a second component, such as wherein the first component comprises (a) a molecule containing one or more acyloxy (ACAC) groups and (b) an epoxy resin; and the second component comprises (c) a molecule containing ketimine and / or aldehyde imine groups. The first and second components are combined before being coated onto a substrate.

[0087] Prior to applying the intumescent coating composition of the present invention, a second coating composition, such as a primer or sealer, may be applied to the surface of the substrate. The second coating composition may be applied by a method selected from electrodeposition, spraying, dip coating, roller coating, and curtain coating.

[0088] When applied to a substrate, the intumescent coating composition can form a coating on the substrate having a dry film thickness in the range of 0.1 to 20 mm, such as in the range of 0.5 to 20 mm, in the range of 0.5 to 18 mm, or in the range of 0.8 to 16 mm, as measured according to ASTM D1005-95 (2020).

[0089] As described above, once applied to a substrate, the intumescent coating composition can have a surface drying time of less than or equal to 200 minutes at 23°C and 40% relative humidity, such as less than or equal to 175 minutes, less than or equal to 150 minutes, or less than or equal to 125 minutes (ASTM-D1640-2014), and the surface drying time can be in the range of 50 to 200 minutes, for example in the range of 60 to 175 minutes, in the range of 70 to 150 minutes, or in the range of 50 to 125 minutes.

[0090] The substrate may be part of a larger structure, which includes an intumescent coating composition applied to the substrate as described herein.

[0091] As used herein, "acyloxy group" or "ACAC group" refers to a functional group in a molecule according to the following formula:

[0092]

[0093] Where R 1 It is a bifunctional C1-C4 alkyl radical, such as methylene; and R 2 It is a C1-C4 alkyl group, such as methyl. When R 1 and R 2 When it is C1, the ACAC group conforms to the formula −OCO-CH2COCH3 and / or structure .

[0094] As used herein, the term "aldehydeimine" refers to a compound characterized by the presence of a double bond connecting carbon and nitrogen atoms, which is formed by the condensation of an aldehyde with an ammonia or primary amine.

[0095] As used herein, the term “surface drying time” refers to the length of time from when a coating is applied until it has hardened, such that the coated surface or film does not show any unwanted marks, detachment, loosening, wrinkling or other forms of deformation when subjected to testing (as a non-limiting example, those tests specified in ASTM-D1640 (2014)).

[0096] As used herein, the term “dry film thickness” or “DFT” refers to the measured thickness of the dried and / or cured film of a coating as determined according to ASTM D1005-95 (2020).

[0097] As used herein, the term "epoxide equivalent weight" refers to the epoxy content of an epoxy resin or epoxy reactive diluent or glycidyl ether. Epoxide equivalent weight can be measured first and completed by titration according to ASTM D1652 (2019). Epoxide equivalent weight reflects the number of grams of epoxy resin required to obtain 1 mole of epoxy groups (g / epoxide equivalent).

[0098] As used herein, the term "expanding agent" refers to a flame retardant that may be included in intumescent coatings to provide, but is not limited to, low smoke, low toxicity, carbonization, coating strength, and / or foaming.

[0099] As used herein, the term "intumescent coating" refers to a protective layer of material that works through a chemical reaction generated by heat, resulting in swelling and the formation of an insulating layer on the surface, as a non-limiting example for fire and corrosion protection of structures.

[0100] As used herein, the term "ketoimine" refers to a compound characterized by the presence of a double bond connecting carbon and nitrogen atoms, which is formed by the condensation of a ketone with an ammonia or primary amine.

[0101] As used herein, unless otherwise described, the term "molecular weight" refers to the weight-average molecular weight of a polymer or oligomer, determined by gel permeation chromatography (GPC) using appropriate polystyrene standards.

[0102] As used herein, the term "phenolic resin" refers to a phenol-formaldehyde resin that can be produced by reacting phenol and formaldehyde to provide an amorphous (non-crystalline) thermoplastic.

[0103] As used herein, the terms “oligomer,” “oligomeric,” “polymer,” or “polymeric” refer to large or macromolecular compounds, i.e., compounds having a relatively high molecular weight (e.g., 500 Da or greater) whose structure comprises multiple repeating units actually or conceptually derived from relatively low molecular weight chemicals, and include, as non-limiting examples, prepolymers, oligomers, homopolymers, and copolymers. The term “resin” may be used interchangeably with “polymer.” The term “monomer” or “monomeric” refers to a compound that can provide the building blocks for the structure of an oligomer or polymer.

[0104] As used herein, the term "thermoplastic" refers to a resin in which the polymer chains are not covalently linked together and thus can undergo liquid flow upon heating and is soluble in certain solvents.

[0105] aspect

[0106] Aspect 1: An intumescent coating composition comprising:

[0107] (a) A molecule containing one or more acyloxy groups;

[0108] (b) Epoxy resin;

[0109] (c) Molecules containing ketimine and / or aldehyde imine groups; and

[0110] (d) Expanding agent.

[0111] Aspect 2: The intumescent coating composition according to aspect 1, wherein the intumescent coating composition is substantially free of (less than 1% by weight), substantially free of (less than 0.1% by weight), or completely free of (undetectable) independent gas sources.

[0112] Aspect 3: An intumescent coating composition according to any one of Aspects 1 or 2, wherein the intumescent coating composition does not contain melamine or a melamine-containing compound.

[0113] Aspect 4: An intumescent coating composition according to any of the foregoing aspects, wherein the molecule comprising one or more acyloxy end groups comprises an acetyloxy end group according to the following formula:

[0114]

[0115] Wherein R1 is a bifunctional C1-C4 alkyl radical, such as methylene; and R2 is a C1-C4 alkyl radical, such as methyl.

[0116] Aspect 5. The intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy group end groups has a molecular weight of 300 to 5,000 g / mol.

[0117] Aspect 6. The intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy groups has a molecular weight of less than 5,000 g / mol, such as less than 3,000 g / mol, less than 1,500 g / mol, less than 1,250 g / mol, or less than 1,000 g / mol.

[0118] Aspect 7. An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy groups has a molecular weight of 500 to 3,000 g / mol, such as 350 to 1,500 g / mol or 500 to 1,000 g / mol.

[0119] Aspect 8. The intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyloxy-terminal groups comprises one or more compounds according to the following formula:

[0120]

[0121] Aspect 9: An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy group ends is present in the intumescent coating composition in an amount ranging from 5% to 30% by weight based on the total weight of the intumescent coating composition.

[0122] Aspect 10: An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy group ends is present in the intumescent coating composition in an amount of at least 5% by weight, such as at least 10% by weight, at least 15% by weight, or at least 20% by weight, based on the total weight of the intumescent coating composition, and may be present in an amount of up to 30% by weight, such as up to 20% by weight, or up to 10% by weight, based on the total weight of the intumescent coating composition.

[0123] Aspect 11: An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising one or more acyl oxy group end groups may be present in the intumescent coating composition in an amount ranging from 5 to 25% by weight, such as 5 to 20% by weight, 10 to 30% by weight, 10 to 25% by weight, 15 to 30% by weight, 15 to 20% by weight, 20 to 30% by weight, 20 to 25% by weight, or 25 to 30% by weight, based on the total weight of the intumescent coating composition.

[0124] Aspect 12: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin comprises a reaction product of a polyhydroxy compound such as a polyvalent phenol or a phenol-aldehyde condensate with an epihaloalcohol or a precursor thereof.

[0125] Aspect 13: An intumescent coating composition according to any of the foregoing aspects, wherein the epoxy resin comprises one or more of the following:

[0126] a) The reaction products of epichlorohydrin with bisphenol A, F or S;

[0127] b) The reaction product of epichlorohydrin and bisphenol S;

[0128] c) Epoxy phenolic resins based on phenol or cresol;

[0129] d) Aromatic glycidyl amine resins;

[0130] e) Epoxy resins that do not have aromatic structural units;

[0131] f) Aliphatic or cycloaliphatic polyepoxides;

[0132] and their combinations or mixtures.

[0133] Aspect 14: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin has an epoxide equivalent weight in the range of 60 to 1000 molar epoxy groups per 100g resin.

[0134] Aspect 15: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin has an epoxide equivalent weight in the range of 100 to 500, such as 150 to 250 molar epoxy groups per 100g resin.

[0135] Aspect 16: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin is present in the intumescent coating composition in a range of 3 to 9.9% by weight based on the total weight of the intumescent coating composition.

[0136] Aspect 17: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin is present in the intumescent coating composition in an amount of at least 3% by weight, such as at least 5% by weight, or at least 7% by weight, based on the total weight of the intumescent coating composition, and may be present in an amount of up to 9.9% by weight, such as up to 9.2% by weight, or up to 8.5% by weight.

[0137] Aspect 18: An intumescent coating composition according to any of the preceding aspects, wherein the epoxy resin is present in the intumescent coating composition in an amount of 3 to 9.2% by weight, such as 3 to 8.5% by weight, 5 to 9.9% by weight, 5 to 9.2% by weight, 5 to 8.5% by weight, 7 to 9.9% by weight, 7 to 9.2% by weight, or 7 to 8.5% by weight, based on the total weight of the intumescent coating composition.

[0138] Aspect 19. An intumescent coating composition according to any of the preceding aspects, wherein the epoxide resin comprises a polyepoxide comprising one or more of the following: phenolic resins, such as reaction products of epihaloalcohols and aldehydes with monohydric or polyhydric phenols; polyglycidyl ethers of polyaromatic alcohols, such as diphenols comprising resorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-ethane; bis(2-hydroxynaphthalene) Polyglycidyl ethers derived from polyols such as ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,2,6-hexanetriol, glycerol, and / or trimethylolpropane; polyglycidyl ethers of polycarboxylic acids, such as those produced by reacting epoxides such as epichlorohydrin with aliphatic or aromatic polycarboxylic acids such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid, and / or dimer linoleic acid; and / or epoxidized polyepoxide resins derived from olefinically unsaturated cycloaliphatic materials.

[0139] Aspect 20: An intumescent coating composition according to any of the preceding aspects, wherein the molecule containing the ketimine group is a reaction product of a polyamine and a ketone-containing molecule.

[0140] Aspect 21: An intumescent coating composition according to any of the preceding aspects, wherein the molecule containing the ketimine group is a reaction product of a polyamine and a ketone-containing molecule to form a polyamine / ketone product, and subsequently the remaining nucleophilic group in the polyamine / ketone product is reacted with an epoxide-containing molecule to form the molecule containing the ketimine group.

[0141] Aspect 22: An intumescent coating composition according to any one of Aspects 20 or 21, wherein the ketone-containing molecule comprises a ketone represented by the following formula:

[0142]

[0143] R and R' are alkane with 1 to 12 carbon atoms, respectively.

[0144] Aspect 23: An intumescent coating composition according to any one of Aspects 20 to 22, wherein the ketone-containing molecule comprises one or more of acetone, diethyl ketone, methyl isobutyl ketone, pentanone, cyclohexanone, ethylpentyl ketone, isophorone, and decanone.

[0145] Aspect 24: An intumescent coating composition according to any of the preceding aspects, wherein the molecule containing an aldehyde imine group is a reaction product of a polyamine and an aldehyde-containing molecule.

[0146] Aspect 25: An intumescent coating composition according to any of the preceding aspects, wherein the molecule containing the aldehyde imine group is a reaction product of a polyamine and an aldehyde-containing molecule to form a polyamine / aldehyde product, and subsequently the remaining nucleophilic groups in the polyamine / aldehyde product are reacted with an epoxide-containing molecule to form the molecule containing the aldehyde imine group.

[0147] Aspect 26: An intumescent coating composition according to any one of Aspects 24 or 25, wherein the aldehyde-containing molecule comprises an aldehyde represented by the following formula:

[0148] RC(O)H

[0149] Where R is an alkane with between 1 and 12 carbon atoms.

[0150] Aspect 27: An intumescent coating composition according to any one of Aspects 24 to 26, wherein the aldehyde-containing molecule comprises one or more of isobutyraldehyde, hydroxybutyraldehyde, and hydroxycitronellol.

[0151] Aspect 28: An intumescent coating composition according to any one of Aspects 20 to 27, wherein the polyamine comprises a compound according to the following formula:

[0152] H2N —(R 5 —NH) n —R 6 —NH2

[0153] Where R 5 and R 6 It can independently be an alkylene group containing 2 to 6 carbon atoms, such as 2 to 4 carbon atoms, and

[0154] Where n is 1 to 6, such as an integer from 1 to 3.

[0155] Aspect 29: The intumescent coating composition according to aspect 28, wherein the alkylene group includes a cycloalkylene group or an alkylene group containing an ether-oxygen atom, such as diethylenetriamine, dipropylenetriamine and dibutyltriamine.

[0156] Aspect 30: An intumescent coating composition according to any one of Aspects 20 to 25, wherein the ketone-modified polyamine is a reaction product of an aliphatic diamine and an aliphatic ketone: the aliphatic diamine comprises isophorone diamine, ethylenediamine, 1,2-diaminopropane, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,8-diaminooctane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4-trimethyl-1,6- Diaminohexane, 2,4,4-trimethyl-1,6-diaminohexane, 1,11-diaminoundecane, 1,12-diaminododecane, 1,3-cyclohexanediamine, 1,4-cyclohexanediamine, 1-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4'-diamino-dicyclohexylmethane, 4,4'-diamino-dicyclohexylmethane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylmethane and / or 3,3'-diethyl-4,4'-diamino-dicyclohexylmethane;

[0157] The aliphatic ketones include acetone, methyl ethyl ketone, methyl isobutyl ketone, and / or methyl pentyl ketone.

[0158] Aspect 31: An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising ketimine and / or aldehyde imine groups has a weight-average molecular weight in the range of 300 g / mol to 10,000 g / mol, for example 500 g / mol to 5,000 g / mol or in the range of 600 g / mol to 1200 g / mol, as determined by gel permeation chromatography using polystyrene standards.

[0159] Aspect 32: An intumescent coating composition according to any of the preceding aspects, wherein the molecule comprising ketimine and / or aldehyde imine groups has at least two ketimine and / or aldehyde imine groups per molecule, such as a range of 2 to 25 ketimine and / or aldehyde imine groups per molecule or a range of 3 to 6 ketimine and / or aldehyde imine groups per molecule.

[0160] Aspect 33: An intumescent coating composition according to any one of Aspects 21 to 28, wherein the epoxide-containing molecule comprises an epoxy resin having an epoxide equivalent weight in the range of 60 to 1000, such as 100 to 500, or 150 to 250 molar epoxy groups per 100 g of resin.

[0161] Aspect 34: An intumescent coating composition according to any one of Aspects 21 to 33, wherein the epoxide-containing molecule comprises an epoxy resin comprising a reaction product of a polyhydroxy compound such as a polyphenol or a phenol-aldehyde condensate with an epihaloalcohol or a precursor thereof.

[0162] Aspect 35: An intumescent coating composition according to any one of Aspects 21 to 34, wherein the epoxide-containing molecule comprises an epoxy resin, the epoxy resin comprising:

[0163] a) The reaction products of epichlorohydrin with bisphenol A, F or S;

[0164] b) The reaction product of epichlorohydrin and bisphenol S;

[0165] c) Epoxy phenolic resins based on phenol or cresol;

[0166] d) Aromatic glycidyl amine resins;

[0167] e) Epoxy resins that do not have aromatic structural units;

[0168] f) Aliphatic or cycloaliphatic polyepoxides;

[0169] and their combinations or mixtures.

[0170] Aspect 36: An intumescent coating composition according to any one of Aspects 21 to 35, wherein the epoxide-containing molecule comprises an epoxide resin comprising a polyepoxide, the polyepoxide comprising one or more of the following: phenolic resins, such as reaction products of epihaloalcohols with aldehydes and monohydric or polyhydric phenols; polyglycidyl ethers of polyaromatic alcohols, such as diphenols comprising resorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-ethane; Bis(2-hydroxynaphthyl)methane, 1,5-hydroxynaphthalene and / or 4,4'-isopropylidene diphenol; polyglycidyl ethers derived from polyols such as ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,2,6-hexanetriol, glycerol and / or trimethylolpropane; polyglycidyl ethers of polycarboxylic acids, such as those produced by reacting epoxides such as epichlorohydrin with aliphatic or aromatic polycarboxylic acids such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid and / or dimer linoleic acid; and / or epoxidized polyepoxide resins derived from olefinically unsaturated cycloaliphatic materials.

[0171] Aspect 37: An intumescent coating composition according to any of the preceding aspects, wherein the molecules comprising ketimine and / or aldehyde imine groups are present in the intumescent coating composition in an amount of at least 10% by weight, such as at least 20% by weight, at least 25% by weight, or at least 30% by weight, based on the total weight of the intumescent coating composition, and the molecules comprising ketimine and / or aldehyde imine groups are present in the intumescent coating composition in an amount of up to 40% by weight, such as up to 30% by weight, or up to 20% by weight, based on the total weight of the intumescent coating composition. In the composition, the molecule comprising ketimine and / or aldehyde imine groups is present in the intumescent coating composition in an amount ranging from 10 to 40% by weight, such as in the range of 10 to 30% by weight, in the range of 10 to 20% by weight, in the range of 15 to 40% by weight, in the range of 10 to 30% by weight, in the range of 15 to 20% by weight, in the range of 20 to 40% by weight, in the range of 20 to 30% by weight, in the range of 25 to 40% by weight, or in the range of 25 to 30% by weight.

[0172] Aspect 38: An intumescent coating composition according to any one of Aspects 1 or 4 to 30, wherein the intumescent agent comprises one or more of the following: melamine and / or melamine derivatives, such as melamine salts, melamine-formaldehyde, hydroxymethylated melamine, hexamethoxymethylmelamine, melamine monophosphate, bis(melamine phosphate), melamine dihydroxyphosphate, and mixtures or combinations thereof.

[0173] Aspect 39: An intumescent coating composition according to any one of Aspects 1 or 3 to 38, wherein the intumescent agent comprises a boron-containing compound, such as boric acid, and borates, such as ammonium pentaborate, zinc borate, sodium borate, lithium borate, aluminum borate, magnesium borate, and borosilicates, and mixtures or combinations thereof.

[0174] Aspect 40: An intumescent coating composition according to any of the preceding aspects, wherein the intumescent agent comprises one or more of a carbon source, an acid source, reinforcing fibers and / or inorganic additives, wherein the carbon source comprises an aromatic compound and / or tall oil fatty acid.

[0175] Aspect 41: The intumescent coating composition according to aspect 36, wherein the carbon source is an aromatic compound containing at least one aromatic ring, such as two, three, or four aromatic rings, such as a benzene ring, a naphthalene ring, an anthracene ring, or a phenanthrene ring, and

[0176] The aromatic compound optionally contains at least one functional substituent, such as a hydroxyl, carboxyl, mercapto, and / or amino group.

[0177] Aspect 42: The intumescent coating composition according to aspect 41, wherein the aromatic compound comprises one or more of bisphenol A, bisphenol B and bisphenol F.

[0178] Aspect 43: An intumescent coating composition according to any one of aspects 40 to 42, wherein the aromatic compound comprises an aromatic compound having a long-chain hydrocarbon substituent, such as a saturated or unsaturated hydrocarbon having a straight-chain or branched alkyl and / or alkenyl and / or alkynyl group having 6 to 20 carbon atoms, such as 6 to 18 carbon atoms, or 6 to 15 carbon atoms;

[0179] The long-chain hydrocarbon group optionally contains 1 to 3 unsaturated bonds, such as double bonds and / or alkyne bonds.

[0180] Aspect 44: An intumescent coating composition according to any one of aspects 40 to 43, wherein the carbon source is present in the intumescent coating composition in a range of 0.5 to 50% by weight, such as 10 to 18% by weight, 11 to 17% by weight, or 12 to 16% by weight, based on the weight of the intumescent coating composition.

[0181] Aspect 45: An intumescent coating composition according to any one of aspects 40 to 44, wherein the acid source comprises one or more of the following: phosphates, such as sodium phosphate, potassium phosphate or ammonium phosphate, ammonium polyphosphate (APP), monoammonium phosphate, diammonium phosphate, trichloroethyl phosphate (TCEP), trichloropropyl phosphate (TCPP), ammonium pyrophosphate and triphenyl phosphate; sulfonates, such as sodium sulfonate, potassium sulfonate, ammonium sulfonate and p-toluenesulfonate; and sulfates, such as sodium sulfate, potassium sulfate and ammonium sulfate.

[0182] Aspect 46: An intumescent coating composition according to any one of aspects 40 to 42, wherein the acid source is present in the intumescent coating composition in an amount ranging from 5 to 30% by weight, such as from 5 to 25% by weight, from 5 to 20% by weight, or from 5 to 15% by weight, based on the total weight of the intumescent coating composition.

[0183] Aspect 47: An intumescent coating composition according to any one of aspects 40 to 46, wherein the reinforcing fiber comprises one or both of inorganic fibers and organic fibers.

[0184] Aspect 48: The intumescent coating composition according to aspect 47, wherein the inorganic fiber comprises one or more of the following: carbide fibers, such as boron carbide fibers, silicon carbide fibers and niobium carbide fibers; nitride fibers, such as silicon nitride fibers; boron-containing fibers, such as boron fibers and boride fibers; silicon-containing fibers, such as silicon fibers, alumina-boron-silica fibers, alkali-free aluminum borate fibers, alkali-free or low-alkali sodium-calcium-aluminum borosilicate fibers, alkali sodium-calcium-silicate fibers, S-glass fibers, inorganic glass fibers, quartz fibers; ceramic fibers and basalt fibers.

[0185] Aspect 49: An intumescent coating composition according to any one of aspects 40 to 48, wherein the reinforcing fiber is present in the intumescent coating composition in a range of 0 to 5% by weight, such as in a range of 1 to 4% by weight or in a range of 2 to 5% by weight, based on the total weight of the intumescent coating composition.

[0186] Aspect 50: An intumescent coating composition according to any one of Aspects 40 to 49, wherein the inorganic additive is present in the intumescent coating composition in an amount ranging from 0 to 50% by weight, such as from 15 to 40% by weight, from 15 to 35% by weight, from 15 to 30% by weight, or from 15 to 25% by weight, based on the total weight of the intumescent coating composition.

[0187] Aspect 51: An intumescent coating composition according to any of the preceding aspects, wherein the intumescent coating composition has a surface drying time of less than or equal to 200 minutes, such as less than or equal to 175 minutes, less than or equal to 150 minutes, or less than or equal to 125 minutes at 23°C and 40% relative humidity (ASTM-D1640-2014), and the surface drying time may be in the range of 50 to 200 minutes, such as in the range of 60 to 175 minutes, in the range of 70 to 150 minutes, or in the range of 50 to 125 minutes.

[0188] Aspect 52: A coated substrate, wherein at least a portion of the surface of the substrate is coated with an intumescent coating composition according to any one of aspects 1 to 51.

[0189] Aspect 53: The coated substrate according to aspect 52, wherein the substrate includes one or more of concrete, wood, plastic, fiberglass and rigid metal substrates such as ferrous metals, aluminum, aluminum alloys and copper.

[0190] Aspect 54: The coated substrate according to aspect 53, wherein the ferrous metal includes one or more of cold-rolled steel, galvanized (zinc-coated) steel, electro-galvanized steel, stainless steel, pickled steel, zinc-iron alloy, and combinations or composites of ferrous and non-ferrous metals.

[0191] Aspect 55: A method of applying an intumescent coating composition, comprising:

[0192] The intumescent coating composition according to any one of aspects 1 to 51 is applied to the substrate.

[0193] Aspect 56: The method according to aspect 55 includes cleaning and / or degreasing at least a portion of the surface of the substrate prior to applying the intumescent coating composition.

[0194] Aspect 57: The method according to any one of Aspects 55 or 56, wherein the intumescent coating composition is a multi-component composition comprising a first component and a second component.

[0195] The first component comprises (a) a molecule containing one or more acyloxy group terminals and (b) an epoxy resin; and the second component comprises (c) a molecule containing ketimine and / or aldehyde imine groups; and

[0196] The first component and the second component are combined before being coated onto the substrate.

[0197] Aspect 58: The method according to any one of Aspects 55 to 57, wherein a second coating composition, such as a primer or a sealer, is applied to the surface of the substrate prior to applying the intumescent coating composition.

[0198] Aspect 59: The method according to aspect 58, wherein the second coating composition is applied by a method selected from electrodeposition, spraying, dipping, roller coating and curtain coating.

[0199] Aspect 60: The method according to any one of aspects 55 to 59, wherein the intumescent coating composition is applied to the substrate using one or more methods selected from brushing, flow coating and spraying.

[0200] Aspect 61: The method according to any one of Aspects 55 to 60, wherein the intumescent coating composition forms a coating on the substrate having a dry film thickness in the range of 0.1 to 20 mm, such as in the range of 0.5 to 20 mm, in the range of 0.5 to 18 mm, or in the range of 0.8 to 16 mm, as measured according to ASTM D1005-95 (2020).

[0201] Aspect 62: The method according to any one of Aspects 55 to 61, wherein the intumescent coating composition has a surface drying time of less than or equal to 200 minutes, such as less than or equal to 175 minutes, less than or equal to 150 minutes, or less than or equal to 125 minutes at 23°C and 40% relative humidity (ASTM-D1640-2014); and the surface drying time may be in the range of 50 to 200 minutes, such as in the range of 60 to 175 minutes, in the range of 70 to 150 minutes, or in the range of 50 to 125 minutes.

[0202] Aspect 63: A structure wherein at least a portion of the substrate of the structure comprises the intumescent coating composition coated according to any one of aspects 55 to 62.

[0203] Example

[0204] The following examples are presented to illustrate the general principles of this disclosure. This disclosure should not be construed as being limited to the specific examples presented.

[0205] Various coating formulations (formulations 1-8) were prepared using the ingredients shown in Table 1. The base material for each coating formulation was prepared by dispersing all components at high speed in a disperser until the particle size in the formulation was less than 100 micrometers. The hardener for each coating formulation was prepared by dispersing all components at high speed in a disperser until the particle size in the formulation was less than 100 micrometers. The dispersion speed and dispersion plate size used were 1200 rpm and 80 mm, respectively, with a container diameter of 180 mm. Just before coating, the base material and hardener were mixed in the relative amounts shown in the table below.

[0206] Comparison Example 1

[0207] Commercial fire retardant products based on epoxyamine technology (PPG Pitt-char NX) were used for comparison of surface drying time.

[0208] Comparison Example 2

[0209] A single-component solvent-based acrylic system (AkzoNobel Interchar 2060) was used to compare surface drying times.

[0210] Comparison Example 3

[0211] A single-component waterborne acrylic system (PPG SteelGuard 651) was used to compare surface drying times.

[0212] Test methods

[0213] A. Dry film thickness

[0214] For the purposes of this disclosure, the dry film thickness was measured one day after drying using an Elcometer 500 digital coating thickness gauge, according to the ASTM D1005-95 (2020) test method.

[0215] B. Surface drying time

[0216] To test surface drying (also known as complete drying) time, apply maximum downward pressure to the membrane using your thumb, twisting it 90 degrees. If no signs of loosening, peeling, twisting, or other deformation of the membrane are observed, the sample is considered "surface dry".

[0217] C. Shore D hardness

[0218] For the purposes of this disclosure, Shore D hardness was measured using a Hildebrand HD3000 Shore D hardness tester, ASTM D2240, DIN 53 505, or ISO 868 test methods. Other methods and instruments may be used where only a comparative understanding of hardness is required.

[0219] As shown in Table 1, Component A of the intumescent coating includes an acetyl acetoxy resin as the ACAC resin, and an epoxy resin as a binder is included and reacted to produce an irreversible enamine as described herein. It includes xylene as a solvent, polyester phosphate salts as wetting and dispersing additives, an organophilic folin silicate as a rheology modifier, castor oil derivatives as a thixotropic agent, titanium dioxide as a pigment, and pentaerythritol as a carbon source for the intumescent agent. When included, melamine is a gas source, ammonium polyphosphate is an acid source, and mineral fibers are engineered mineral fibers for reinforcement. Component B contains polyketimide as a curing agent.

[0220] Table 1. Examples

[0221]

[0222] 1 Prepared according to Example A of U.S. Patent No. 5,288,802

[0223] 2 EPON 1001-x-75, HEXION INC.

[0224] 3 EPONEX 1510, HEXION INC.

[0225] 4 EPOKUKDO YDF-170, Kukdo Chemical

[0226] 5 DISPERBYK 103, BYK-CHEMIE GMBH

[0227] 6 GARAMITE 1958,BYK-CHEMIE GMBH

[0228] 7 THIXATROL ST, ELEMENTIS SPECIALTIES, INC.

[0229] 8 KRONOS 2310, Kronos International, Inc.

[0230] 9 FR CROS 484, Chemische Fabrik Budenheim KG

[0231] 10 COATFORCE CF30,ROCKWOOL A / S AKTIESELSKAP

[0232] 11 Prepared according to Example C of U.S. Patent No. 5,288,802

[0233] The base material (Part A) and hardener (Part B) were mixed using a mixer or scraper until the mixture became uniform in color and free of lumps. The paint formulations were then applied separately to 150 x 75 x 1.2 mm sandblasted steel plates using a trowel, resulting in a dry film thickness (DFT) of approximately 2 mm. The coated panels were tested for 10 minutes under torch flames at 1200°C and -50°C, at a gas pressure of 2 bar and a burner diameter of 30 mm. The coefficient of thermal expansion (defined as the ratio between the thickness of the expanded paint and the thickness of the original paint), the formation of char, and its adhesion to the substrate were evaluated. The results are summarized in Tables 1 and 2 below.

[0234] Table 2. Characteristics of Instances

[0235]

[0236] Table 2.1 Shore D hardness of examples by day

[0237]

[0238] The surface drying times of Examples 1 to 8 were significantly shorter than those of Comparative Examples 1, 2, and 3. No significant differences were observed between examples containing melamine (Examples 1 to 6) and those not containing melamine (Examples 7 and 8) as gas sources.

[0239] Although specific embodiments of the present disclosure have been described above for illustrative purposes, it will be apparent to those skilled in the art that many detailed changes may be made to the present disclosure without departing from the scope of the disclosure as defined in the appended claims.

Claims

1. An intumescent coating composition comprising: (a) A molecule containing one or more acyloxy groups; (b) Epoxy resin; (c) Molecules containing ketimine and / or aldehyde imine groups; and (d) Expanding agent.

2. The intumescent coating composition according to claim 1, wherein the intumescent coating composition contains less than 1% by weight of a separate gas source.

3. The intumescent coating composition according to any one of claims 1 or 2, wherein the intumescent coating composition does not contain melamine or melamine-containing compounds.

4. The intumescent coating composition according to any preceding claim, wherein the molecule comprising one or more acyloxy-terminal groups contains an acetylacetoxy-terminal group according to the following formula: Wherein R1 is a bifunctional C1-C4 alkyl radical, such as methylene; and R2 is a C1-C4 alkyl radical, such as methyl.

5. The intumescent coating composition according to any of the preceding claims, wherein the molecule comprising one or more acyloxy group terminals has a molecular weight of 300 to 5,000 g / mol.

6. The intumescent coating composition according to any preceding claim, wherein the molecule comprising one or more acyloxy-terminal groups comprises one or more compounds according to the following formula:

7. The intumescent coating composition according to any preceding claim, wherein the epoxy resin comprises a reaction product of a polyhydroxy compound such as a polyvalent phenol or a phenol-aldehyde condensate with an epihaloalcohol or a precursor thereof, wherein the epoxy resin optionally comprises one or more of the following: a) The reaction products of epichlorohydrin with bisphenol A, F or S; b) Epoxy phenolic resins based on phenol or cresol; c) Aromatic glycidyl amine resins; d) Epoxy resins that do not have aromatic structural units; e) Aliphatic or cycloaliphatic polyepoxides; f) Polyepoxides, said polyepoxides comprising one or more of the following: phenolic resins, such as reaction products of epihaloalcohols and aldehydes with monohydric or polyhydric phenols; polyglycidyl ethers of polyaromatic alcohols, such as diphenols comprising resorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-ethane; bis(2-hydroxynaphthyl)methane, 1,5-hydroxynaphthalene and / or 4, 4'-Isopropylidene diphenol; polyglycidyl ethers derived from polyols such as ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,2,6-hexanetriol, glycerol, and / or trimethylolpropane; polyglycidyl ethers of polycarboxylic acids, such as those produced by reacting epoxides such as epichlorohydrin with aliphatic or aromatic polycarboxylic acids such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid, and / or dimer linoleic acid; and / or epoxidized polyepoxide resins derived from olefinically unsaturated alicyclic materials; and h) its combination or mixture.

8. The intumescent coating composition according to any of the preceding claims, wherein the molecule containing the ketimine group is a reaction product of a polyamine and a ketone-containing molecule; optionally, the reaction product of the polyamine and the ketone-containing molecule is included to form a polyamine / ketone product, wherein the remaining nucleophilic group in the polyamine / ketone product is reacted with an epoxide-containing molecule to form a molecule containing the ketimine group; optionally, wherein the ketone-containing molecule comprises a ketone represented by the following formula: R and R' are independently alkanes having between 1 and 12 carbon atoms; such as one or more of acetone, diethyl ketone, methyl isobutyl ketone, pentanone, cyclohexanone, ethylpentyl ketone, isophorone, and decanone.

9. The intumescent coating composition according to any of the preceding claims, wherein the molecule containing the aldehyde-imine group is a reaction product of a polyamine and an aldehyde-containing molecule; optionally, wherein the molecule containing the aldehyde-imine group is a reaction product of a polyamine and an aldehyde-containing molecule to form a polyamine / aldehyde product, wherein the remaining nucleophilic group in the polyamine / aldehyde product is reacted with an epoxide-containing molecule to form the molecule containing the aldehyde-imine group; and / or wherein the aldehyde-containing molecule comprises an aldehyde represented by the following formula: RC(O)H Where R is an alkane with between 1 and 12 carbon atoms; and Optionally, the aldehyde-containing molecule comprises one or more of isobutyraldehyde, hydroxybutyraldehyde, and hydroxycitronellol.

10. The intumescent coating composition according to any one of claims 8 or 9, wherein the polyamine comprises a compound according to the following formula: H2N —(R 5 —NH) n —R 6 —NH2 Where R 5 and R 6 It can independently be an alkylene group containing 2 to 6 carbon atoms, such as 2 to 4 carbon atoms, and Wherein n is 1 to 6, such as an integer from 1 to 3; optionally, wherein the alkylene group comprises a cycloalkylene group or an alkylene group containing an ether-oxygen atom, such as diethylenetriamine, dipropylenetriamine and dibutyltriamine.

11. The intumescent coating composition according to any one of claims 8 to 10, wherein the ketone-modified polyamine is a reaction product of an aliphatic diamine and an aliphatic ketone. The aliphatic diamines include isophorone diamine, ethylenediamine, 1,2-diaminopropane, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,8-diaminooctane, 2-methyl-1,5-pentanediamine, 2,5-diamino-2,5-dimethylhexane, 2,2,4-trimethyl-1,6-diaminohexane, and 2,4,4-trimethyl-1,6-diaminohexane. 1,11-Diaminoundecane, 1,12-Diaminododecane, 1,3-Cyclohexanediamine, 1,4-Cyclohexanediamine, 1-Amino-3,3,5-Trimethyl-5-aminomethyl-cyclohexane, 2,4'-Diamino-dicyclohexylmethane, 4,4'-Diamino-dicyclohexylmethane, 3,3'-Dimethyl-4,4'-Diamino-dicyclohexylmethane and / or 3,3'-Diethyl-4,4'-Diamino-dicyclohexylmethane; The aliphatic ketones include acetone, methyl ethyl ketone, methyl isobutyl ketone, and / or methyl pentyl ketone.

12. The intumescent coating composition according to any one of claims 8 to 11, wherein the epoxide-containing molecule comprises an epoxy resin, the epoxy resin comprising a reaction product of a polyhydroxy compound such as a polyvalent phenol or a phenol-aldehyde condensate with an epihaloalcohol or a precursor thereof; optionally wherein the epoxide-containing molecule comprises an epoxy resin, the epoxy resin comprising: a) The reaction products of epichlorohydrin with bisphenol A, F or S; b) Epoxy phenolic resins based on phenol or cresol; c) Aromatic glycidyl amine resins; d) Epoxy resins that do not have aromatic structural units; e) Aliphatic or cycloaliphatic polyepoxides; f) Polyepoxides, said polyepoxides comprising one or more of the following: phenolic resins, such as reaction products of epihaloalcohols and aldehydes with monohydric or polyhydric phenols; polyglycidyl ethers of polyaromatic alcohols, such as diphenols comprising resorcinol, catechol, hydroquinone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-isobutane, 4,4-dihydroxybenzophenone, bis(4-hydroxyphenyl)-1,1-ethane; bis(2-hydroxynaphthyl)methane, 1,5-hydroxynaphthalene and / or 4, 4'-Isopropylidene diphenol; polyglycidyl ethers derived from polyols such as ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,2,6-hexanetriol, glycerol and / or trimethylolpropane; polyglycidyl ethers of polycarboxylic acids, such as those produced by reacting epoxides such as epichlorohydrin with aliphatic or aromatic polycarboxylic acids such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid and / or dimer linoleic acid; and / or epoxidized polyepoxide resins derived from olefinically unsaturated alicyclic materials; as well as g) and its combinations or mixtures.

13. The intumescent coating composition according to any one of claims 1 to 12, wherein the intumescent agent comprises a boron-containing compound, such as boric acid, and borates, such as ammonium pentaborate, zinc borate, sodium borate, lithium borate, aluminum borate, magnesium borate, and borosilicates, and mixtures or combinations thereof, and / or one or more of a carbon source, acid source, reinforcing fiber, and / or inorganic additive comprising an aromatic compound and / or tall oil fatty acid, wherein the carbon source optionally comprises an aromatic compound containing at least one aromatic ring, such as 2, 3, or 4 aromatic rings, such as a benzene ring, naphthalene ring, anthracene ring, or phenanthrene ring, and The aromatic compound may optionally contain at least one functional substituent, such as a hydroxyl, carboxyl, mercapto, and / or amino group.

14. The intumescent coating composition of claim 13, wherein the acid source comprises one or more of the following: phosphates, such as sodium phosphate, potassium phosphate or ammonium phosphate, ammonium polyphosphate (APP), monoammonium phosphate, diammonium phosphate, trichloroethyl phosphate (TCEP), trichloropropyl phosphate (TCPP), ammonium pyrophosphate and triphenyl phosphate; sulfonates, such as sodium sulfonate, potassium sulfonate, ammonium sulfonate and p-toluenesulfonate; and sulfates, such as sodium sulfate, potassium sulfate and ammonium sulfate; and / or The reinforcing fibers described herein comprise one or both of inorganic and organic fibers. The inorganic fibers may optionally include one or more of the following: carbide fibers, such as boron carbide fibers, silicon carbide fibers, and niobium carbide fibers; nitride fibers, such as silicon nitride fibers; boron-containing fibers, such as boron fibers and boride fibers; silicon-containing fibers, such as silicon fibers, alumina-boron-silica fibers, alkali-free aluminum borate fibers, alkali-free or low-alkali sodium-calcium-aluminum borosilicate fibers, alkali sodium-calcium-silicate fibers, S-glass fibers, inorganic glass fibers, quartz fibers; ceramic fibers, and basalt fibers.

15. The intumescent coating composition according to any of the preceding claims, wherein the intumescent coating composition has a surface drying time of less than or equal to 200 minutes at 23°C and 40% relative humidity (ASTM-D1640-2014).

16. A coated substrate, wherein at least a portion of the surface of the substrate is coated with an intumescent coating composition according to any one of claims 1 to 15; The substrates mentioned include concrete, wood, plastic, fiberglass, and rigid metal substrates such as ferrous metals, aluminum, aluminum alloys, and copper, or more thereof; and The ferrous metals mentioned therein include one or more of the following: cold-rolled steel, galvanized (zinc-coated) steel, electro-galvanized steel, stainless steel, pickled steel, zinc-iron alloys, and combinations or composites of ferrous and non-ferrous metals.

17. A method for coating an intumescent coating composition, comprising: Apply the intumescent coating composition according to any one of claims 1 to 15 to a substrate; Optionally, at least a portion of the surface of the substrate is cleaned and / or degreased before applying the intumescent coating composition; Optionally, a second coating composition, such as a primer or a sealer, is applied to the surface of the substrate prior to applying the intumescent coating composition. The intumescent coating composition optionally comprises a multi-component composition, the multi-component composition comprising a first component and a second component; The first component comprises (a) a molecule containing one or more acyloxy terminal groups and (b) an epoxy resin; and the second component comprises (c) a molecule containing ketimine and / or aldehyde imine groups; and The first component and the second component are combined before being coated onto the substrate; and The intumescent coating composition forms a coating on the substrate, the coating having a dry film thickness in the range of 0.1 to 20 mm as measured according to ASTM D1005-95 (2020).

18. The method of claim 18, wherein the intumescent coating composition has a surface drying time in the range of 50 to 200 minutes at 23°C and 40% relative humidity according to ASTM-D1640-2014.

19. A structure wherein at least a portion of the substrate of the structure comprises the intumescent coating composition applied according to any one of claims 17 to 18.

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