Water-based coatings with fireproof and thermal insulation functions, their preparation methods and applications

Abstract

This invention discloses a water-based coating with fire-retardant and thermal insulation functions, its preparation method, and its application, relating to the field of water-based coatings. This water-based coating with fire-retardant and thermal insulation functions, through an innovative raw material ratio, combines inorganic and organic flame retardants, along with surface-treated insulating glass microspheres and a specific ratio of inorganic hybrid emulsion, successfully enabling the coating to simultaneously possess excellent fire-retardant and thermal insulation properties. Test results of Examples 1-3 show that the coatings all achieve a 1-hour fire resistance rating, with the lowest thermal conductivity reduced to 0.042 W / (m·K), far exceeding the performance of the control example, which only possesses basic fire-retardant functions and insufficient thermal insulation performance. When this multifunctional coating is applied to building exteriors, industrial equipment surfaces, and vehicle interiors, it can effectively prevent the spread of fire, ensure personnel safety, reduce energy consumption, and improve energy efficiency.

Description

Technical Field

[0001] This invention relates to water-based coating technology, specifically to water-based coatings with fire-retardant and thermal insulation functions, their preparation methods, and applications. Background Technology

[0002] With increasingly stringent building safety standards and energy efficiency requirements, the development of multifunctional coatings has become a research hotspot in the coatings industry. Traditional fire-retardant coatings often focus on fire resistance while neglecting thermal insulation, leading to excessively high internal temperatures in buildings under high-temperature conditions and increased energy consumption of air conditioning and other cooling equipment. While thermal insulation coatings can effectively reduce internal building temperatures, they may be insufficient in fire protection and unable to meet stringent fire safety requirements.

[0003] Furthermore, with increasing environmental awareness, water-based coatings are gradually becoming the mainstream trend in the coatings industry due to their advantages such as low VOC emissions and environmental friendliness. However, achieving a perfect combination of fireproofing and thermal insulation functions in a water-based system, while maintaining the coating's workability and decorative effect, remains a current technological challenge.

[0004] Therefore, developing a water-based coating that has both excellent fire resistance and good thermal insulation properties is of great significance for improving the energy efficiency of buildings, ensuring personnel safety, and promoting the green development of the coating industry. Summary of the Invention

[0005] The purpose of this invention is to provide water-based coatings with fireproof and thermal insulation functions, their preparation methods, and applications, in order to solve the problems in the prior art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a water-based coating with fireproof and heat insulation functions, comprising the following raw materials in parts by weight: 75-85 parts water, 10-20 parts dispersant, 3-7 parts wetting agent, and 3 parts defoamer, wherein the defoamer is added in two parts, 2 parts in the first part and 1 part in the second part; 280-320 parts flame retardant, 180-220 parts heat-insulating glass microspheres, 380-420 parts inorganic hybrid emulsion, and 3 parts bactericide; wherein the flame retardant is a composite of inorganic flame retardant and organic flame retardant, and the weight ratio of inorganic flame retardant to organic flame retardant is (60-80):(20-40).

[0007] Furthermore, the heat-insulating glass microspheres have a particle size distribution between 5 and 50 micrometers, and their surface is treated with a silane coupling agent. The treated heat-insulating glass microspheres have improved dispersibility in the coating and enhanced adhesion to the substrate.

[0008] Furthermore, the inorganic hybrid emulsion is a copolymer of silicate and acrylate, wherein the silicate content is 30%-50%, and this copolymer imparts excellent weather resistance and chemical stability to the coating.

[0009] Furthermore, the coating may also contain a color modifier, the amount of which is 0.5%-2% of the total weight of the coating, to adjust the color of the coating to meet different decorative needs.

[0010] A method for preparing water-based coatings with fire-retardant and thermal insulation functions includes the following steps:

[0011] Step 1: Add water to the reaction vessel, turn on the stirrer, and adjust the stirring speed to 200-300 rpm;

[0012] Step 2: Add dispersant 200 and wetting agent in sequence, and stir until completely dissolved to form a homogeneous solution;

[0013] Step 3: While stirring continuously, slowly add the flame retardant, controlling the addition speed to avoid excessive local concentration, and continue stirring until the flame retardant is evenly dispersed;

[0014] Step 4: Adjust the stirring speed to 100-200 rpm, add the surface-treated heat-insulating glass microspheres, stir at low speed to avoid breaking the microspheres, and stir for no more than 10 minutes;

[0015] Step 5: Add the inorganic hybrid emulsion, adjust the stirring speed to medium (200-300 rpm), and stir until the mixture is homogeneous and a stable emulsion system is formed;

[0016] Step 6: Add 2 parts of defoamer for the first time and stir until the foam is completely eliminated;

[0017] Step 7: Add 1 part defoamer and 3 parts bactericide, and continue stirring until fully mixed to ensure that the coating is free of bubbles and has antibacterial properties;

[0018] Step 8: Filter the material to obtain a water-based coating with fireproof and heat insulation functions.

[0019] Furthermore, in step three, the addition rate of the flame retardant is controlled at 5%-10% of the total amount per minute, and the temperature inside the reactor is continuously monitored during the addition process to avoid excessive temperature causing the flame retardant to decompose.

[0020] Furthermore, in step four, the addition of the heat-insulating glass microspheres is carried out at a stirring speed of 100-200 rpm, and after addition, the microspheres are further dispersed by ultrasonic treatment.

[0021] The application of water-based coatings with fireproof and thermal insulation functions on building exterior walls can form a continuous coating with excellent fireproof and thermal insulation properties, effectively improving the energy efficiency and safety of buildings. The coating thickness is controlled between 1.5-3mm.

[0022] Water-based coatings with fire-retardant and thermal insulation properties are applied to the surfaces of industrial equipment. These coatings can withstand high-temperature environments, prevent equipment from overheating, provide fire protection, and extend the service life of the equipment. They are suitable for industrial environments with temperatures not exceeding 300°C.

[0023] The application of water-based coatings with fireproof and thermal insulation functions in the interior of vehicles: These coatings can be applied to the interior decoration materials of vehicles such as automobiles, trains, and airplanes, providing fire safety while improving the thermal comfort of the riding environment, and meeting the environmental protection and safety standards for interior materials of vehicles.

[0024] Compared with the prior art, the water-based coating with fireproof and thermal insulation functions, its preparation method, and its application provided by the present invention have the following beneficial effects:

[0025] The water-based coating with fireproofing and thermal insulation functions provided by this invention represents a significant breakthrough in performance, effectively solving the problem of the single function of traditional coatings. Through innovative raw material formulation, inorganic and organic flame retardants are combined, along with surface-treated insulating glass microspheres and a specific ratio of inorganic hybrid emulsion, successfully enabling the coating to simultaneously possess excellent fireproofing and thermal insulation properties. Test results from Examples 1-3 show that the coatings all achieve a 1-hour fire resistance rating, with a minimum thermal conductivity of 0.042 W / (m·K), far exceeding the performance of the control example, which only possesses basic fireproofing and insufficient thermal insulation. When applied to building exteriors, industrial equipment surfaces, and vehicle interiors, this multifunctional coating effectively prevents the spread of fire, ensuring personnel safety, while also reducing energy consumption and improving energy efficiency. For example, in applications on high-rise building exteriors, the indoor temperature in summer is 4-6°C lower than in uncoated buildings, significantly reducing the energy consumption of air conditioning and other refrigeration equipment, providing strong support for energy conservation and emission reduction in the construction industry, and demonstrating significant economic and environmental benefits.

[0026] This invention also excels in environmental friendliness, construction performance, and decorative effect, comprehensively improving the overall quality of water-based coatings. As a water-based coating system, this invention strictly adheres to low VOC emission standards, is environmentally friendly and pollution-free, and effectively avoids the harm to the environment and human health that may be present in traditional coatings. Regarding construction performance, by optimizing the preparation process and strictly controlling parameters such as the addition rate of each raw material, stirring speed, and time, the coating surface is smooth and bubble-free after application, the coating is more uniform, adhesion is significantly improved, and hardness and wear resistance are also enhanced, solving the problems of cracking and peeling of the control example coating and extending the service life of the coating. In terms of decorative effect, color modifiers can be added to the coating as needed to meet different decorative style requirements. Taking Example 1 applied to the exterior wall of a high-rise building as an example, the coating is not only aesthetically pleasing, but also maintains good fire resistance and thermal insulation performance after a year of natural exposure testing, without any quality problems, providing the coating industry with a multifunctional solution that is both environmentally friendly and practical, with excellent decorative effects. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0028] Figure 1 This is a flowchart illustrating the preparation method of the water-based coating with fireproof and heat insulation functions according to the present invention. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0030] Example 1

[0031] Raw material ratio: 80kg water, 15kg dispersant, 5kg wetting agent, 2kg defoamer (primary), 300kg flame retardant (inorganic:organic = 7:3), 200kg heat-insulating glass microspheres (particle size 10-30 microns, silane treated), 400kg inorganic hybrid emulsion (silicate 40%), 1kg defoamer (secondary), and 3kg bactericide.

[0032] Preparation process: The procedure is carried out according to claim 4, with particular attention paid to the addition rate and stirring conditions of the flame retardant and heat-insulating glass microspheres. When adding the flame retardant, the addition rate is controlled at 7% of the total amount per minute, and the temperature inside the reactor is continuously monitored to avoid overheating. After adding the heat-insulating glass microspheres, ultrasonic treatment is used to further promote the dispersion of the microspheres.

[0033] Performance testing: After the coating dried, fire resistance testing (ASTM E119 standard) and thermal insulation performance testing (thermal conductivity measurement) were conducted. The results showed that the coating has excellent fire resistance (1-hour fire resistance) and low thermal conductivity (0.048 W / (m·K)). At the same time, the coating surface is smooth, free of bubbles, and has a good decorative effect.

[0034] Example 2

[0035] Raw material ratio adjustment: water increased to 85kg, flame retardant adjusted to an inorganic:organic ratio of 6:4, total amount kept unchanged at 300kg, dispersant increased to 18kg, wetting agent reduced to 4kg, other raw material ratios slightly adjusted to maintain total consistency.

[0036] Preparation process: Similar to Example 1, but the stirring speed and addition order were adjusted. Before adding the flame retardant, the stirring speed in the reactor was adjusted to 250 rpm, and then the flame retardant was slowly added, controlling the addition rate to 6% of the total amount per minute. After adding the heat-insulating glass microspheres, the dispersion of the microspheres was further promoted by extending the ultrasonic treatment time.

[0037] Performance testing: The coating exhibits better application performance and a more uniform coating appearance. Fire resistance and thermal insulation performance tests show that the coating maintains its excellent fire resistance rating (1-hour fire resistance) and low thermal conductivity (0.052 W / (m·K)), while the coating's adhesion and weather resistance have also been improved.

[0038] Example 3

[0039] Raw material innovation: A new type of nano-insulation material is used to replace part of the insulation glass microspheres. The nano-material accounts for 25% of the insulation component, while the silicate content in the inorganic hybrid emulsion is adjusted to 45%.

[0040] Preparation process: When adding the heat insulation components, first add 150 kg of traditional heat-insulating glass microspheres, then slowly add 50 kg of nano-heat-insulating material, adjusting the stirring parameters to avoid agglomeration of the nanomaterials. Specifically, the stirring speed is as follows: before adding the nanomaterials, the stirring speed is 150 rpm; when adding the nanomaterials, reduce the stirring speed to 100 rpm and continue stirring for 15 minutes; then restore the stirring speed to 200 rpm and continue adding other raw materials.

[0041] Performance testing: The coating's thermal conductivity was further reduced to 0.042 W / (m·K), while its fire resistance remained unaffected, maintaining a fire rating of 1 hour fire resistance. Furthermore, the coating's hardness and abrasion resistance were also improved, making it suitable for applications requiring higher coating performance.

[0042] Comparison Example

[0043] Taking a water-based coating with only basic fire-retardant properties as an example, the coating is mainly composed of the following raw materials (by weight):

[0044] Water: 80-90 parts

[0045] Fire retardant additives (such as aluminum hydroxide, intumescent fire retardants, etc.): 50-100 parts

[0046] Emulsions (such as pure acrylic emulsions, styrene-acrylic emulsions, etc.): 100-150 parts

[0047] Dispersants, defoamers, thickeners, and other additives: appropriate amount

[0048] Preparation method:

[0049] Add water to the reactor and start stirring.

[0050] Add dispersant, defoamer and other additives in sequence, and stir until completely dissolved.

[0051] Slowly add the fire retardant and continue stirring until it is evenly dispersed.

[0052] Add the emulsion, adjust the stirring speed to medium, and stir until well mixed.

[0053] Adjust the viscosity of the coating as needed by adding thickener and stirring until the desired viscosity is achieved.

[0054] The material is filtered out to obtain a water-based coating with only basic fire-retardant properties.

[0055] Application effects and limitations:

[0056] Application effect: The coating showed a certain fire resistance time in fire resistance tests and can effectively prevent the spread of fire within a certain period of time.

[0057] limitation:

[0058] Insufficient thermal insulation performance: The coating is not specially designed with thermal insulation components, which leads to excessively high internal temperatures in buildings under high-temperature environments, increasing the energy consumption of refrigeration equipment.

[0059] Environmental friendliness and construction performance: Although it is a water-based coating, some raw materials may contain substances that are harmful to the environment or human body, and the coating may crack or peel after construction, affecting the decorative effect and service life.

[0060] Limited functionality: It cannot simultaneously meet the needs of fireproofing and thermal insulation, making it difficult to adapt to the urgent requirements of modern buildings for multifunctional coatings.

[0061] The effects of the water-based coatings with fireproof and thermal insulation functions of Examples 1 to 3, their preparation methods, and applications were compared with those of the control examples, and the results are shown in the table below:

[0062] Example number Fire resistance performance (fire resistance time) Thermal insulation performance (0.048W / (m·K)) Environmental protection Construction performance Decorative effect Overall benefits Comparison Example Basic refractory (specific time unknown, assumed to be short) Insufficient (high thermal conductivity) Generally (may contain harmful substances) The coating is prone to cracking and peeling. generally Lower (single function, difficult to meet the needs of modern architecture) Example 1 1-hour fire resistance 0.048 Superior (water-based system, low VOC) The coating is smooth and free of bubbles. good High (meets both fireproofing and thermal insulation requirements) Example 2 1-hour fire resistance 0.052 (slightly higher than Example 1, but still better than the control example) excellent The coating is more uniform and the adhesion is improved. good High performance (optimized for more scenarios) Example 3 1-hour fire resistance 0.042 (optimal) excellent Improved coating hardness and wear resistance good Top-of-the-line (innovative nanomaterials, comprehensively improved performance)

[0063] As shown in the table above, compared to the control example, Examples 1 to 3 significantly improved the overall performance of the water-based coating through innovative raw material ratios and preparation processes. Example 1 successfully combined fireproofing and thermal insulation functions, with the coating exhibiting a 1-hour fire resistance rating and low thermal conductivity (0.048 W / (m·K)), while maintaining excellent environmental friendliness and workability, and providing a good decorative effect. Example 2 further optimized Example 1 by adjusting the raw material ratio and stirring parameters, resulting in a more uniform coating and improved adhesion. Although the thermal conductivity increased slightly, it was still far superior to the control example. Example 3 introduced a novel nano-insulating material, reducing the thermal conductivity to 0.042 W / (m·K), while also significantly improving the coating's hardness and wear resistance, achieving optimal overall performance. These three examples effectively solved the problems of single function, insufficient environmental friendliness, and poor workability in the control example, providing the coating industry with a new multifunctional solution with significant economic and social benefits.

[0064] Application examples

[0065] Application scenario: The coating prepared in Example 1 is applied to the exterior wall decoration of a high-rise building.

[0066] Construction process: A spray coating process is used, with the coating thickness controlled at 2mm. Before construction, the building's exterior wall is cleaned to ensure the surface is free of oil, dust, and other impurities. Construction involves two coats; the second coat is applied after the first coat has dried to a non-sticky state.

[0067] Application Results: The building exterior wall coating is not only aesthetically pleasing, but also performed exceptionally well in actual fire simulation tests, effectively preventing the spread of fire. Simultaneously, the indoor temperature in summer is 4-6°C lower than in uncoated buildings, significantly improving the building's energy efficiency. Furthermore, after a year of natural exposure testing, the coating maintained its excellent fire resistance and thermal insulation properties, without exhibiting cracking or peeling.

[0068] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A water-based coating with fireproof and thermal insulation functions, characterized in that, It is composed of the following raw materials in parts by weight: 75-85 parts water, 10-20 parts dispersant, 3-7 parts wetting agent, 3 parts defoamer (the defoamer is added in two parts, 2 parts in the first part and 1 part in the second part), 280-320 parts flame retardant, 180-220 parts heat-insulating glass microspheres, 380-420 parts inorganic hybrid emulsion, and 3 parts bactericide; wherein, the flame retardant is a complex of inorganic flame retardant and organic flame retardant, and the weight ratio of inorganic flame retardant to organic flame retardant is (60-80):(20-40).

2. The water-based coating with fireproof and thermal insulation functions according to claim 1, characterized in that, The heat-insulating glass microspheres have a particle size distribution between 5 and 50 micrometers and their surface is treated with a silane coupling agent. The treated heat-insulating glass microspheres have improved dispersibility in the coating and enhanced adhesion to the substrate.

3. The water-based coating with fireproof and thermal insulation functions according to claim 1, characterized in that, The inorganic hybrid emulsion is a copolymer of silicate and acrylate, wherein the silicate content is 30%-50%, and the copolymer imparts excellent weather resistance and chemical stability to the coating.

4. The method for preparing a water-based coating with fire-retardant and thermal insulation functions according to any one of claims 1-3, characterized in that, Includes the following steps: Step 1: Add water to the reaction vessel, turn on the stirrer, and adjust the stirring speed to 200-300 rpm; Step 2: Add the dispersant and wetting agent in sequence, and stir until completely dissolved to form a homogeneous solution; Step 3: While stirring continuously, slowly add the flame retardant, controlling the addition speed to avoid excessive local concentration, and continue stirring until the flame retardant is evenly dispersed; Step 4: Adjust the stirring speed to 100-200 rpm, add the surface-treated heat-insulating glass microspheres, stir at low speed to avoid breaking the microspheres, and stir for no more than 10 minutes; Step 5: Add the inorganic hybrid emulsion, adjust the stirring speed to medium (200-300 rpm), and stir until the mixture is homogeneous and a stable emulsion system is formed; Step 6: Add 2 parts of defoamer for the first time and stir until the foam is completely eliminated; Step 7: Add 1 part defoamer and 3 parts bactericide, and continue stirring until fully mixed to ensure that the coating is free of bubbles and has antibacterial properties; Step 8: Filter the material to obtain a water-based coating with fireproof and heat insulation functions.

5. The method for preparing a water-based coating with fire-retardant and thermal insulation functions according to claim 4, characterized in that, In step three, the addition rate of the flame retardant is controlled at 5%-10% of the total amount per minute, and the temperature inside the reactor is continuously monitored during the addition process to avoid excessive temperature causing the flame retardant to decompose.

6. The method for preparing a water-based coating with fire-retardant and thermal insulation functions according to claim 4, characterized in that, In step four, the addition of the heat-insulating glass microspheres is carried out at a stirring speed of 100-200 rpm, and after addition, the microspheres are further dispersed by ultrasonic treatment.

7. The water-based coating with fireproof and thermal insulation functions according to claim 1, characterized in that, The coating may also contain a color modifier, which is added at a rate of 0.5%-2% of the total weight of the coating, to adjust the color of the coating to meet different decorative needs.

8. The application of the water-based coating with fireproof and thermal insulation functions according to claim 1 on building exterior walls, characterized in that, This coating can form a continuous layer with excellent fire resistance and thermal insulation properties.

9. The application of the water-based coating with fireproof and thermal insulation functions according to claim 1 on the surface of industrial equipment, characterized in that, This coating can withstand high-temperature environments, prevent equipment from overheating, and provide fire protection, extending equipment lifespan. It is suitable for industrial environments with temperatures not exceeding 300°C.

10. The application of the water-based coating with fire-retardant and thermal insulation functions according to claim 1 in the interior of a vehicle, characterized in that, This coating can be applied to the interior decoration materials of vehicles such as cars, trains, and airplanes.

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