Thick paste type solvent-free epoxy fireproof coating and application thereof

Abstract

This invention discloses a thick-film solvent-free epoxy fire-retardant coating and its application. The thick-film solvent-free epoxy fire-retardant coating comprises component A and component B. Component A includes the following components: polyester-modified epoxy resin, tall oil fatty acid, glass fiber filaments, thixotropic thickener, rheology modifier, and flame retardant. Component B includes the following components: curing agent, curing accelerator, modifier, glass fiber filaments, thixotropic thickener, rheology modifier, and melamine. The coating formed by applying the above coating to a substrate exhibits excellent adhesion, good wind resistance, water resistance, weather resistance, and durability, and there is no fire risk at the joints.

Description

Technical Field

[0001] This invention relates to the field of coating technology, and more specifically, to a thick-film solvent-free epoxy fire-retardant coating and its application. Background Technology

[0002] Commercially available solvent-free or high-solids epoxy fire-retardant coatings possess excellent sealing properties and environmental resistance. They are resistant to acids, alkalis, salt spray, solvent oils, aging, and chemicals, with a service life exceeding 20 years. They offer high fire resistance, high film strength, and strong corrosion resistance, making them widely applicable in outdoor and marine environments, as well as in the petrochemical industry. Furthermore, epoxy fire-retardant coatings have a high-strength intumescent carbon layer, effectively resisting flames with thermal shock and providing effective fire protection in hydrocarbon fires and jet-type hydrocarbon fires (explosions).

[0003] However, fire-retardant coatings currently have many drawbacks in their application, particularly in terms of fire resistance category and fire rescue waiting time, especially: 1. When hydrocarbons burn, the temperature rises suddenly, which can easily cause fireproof materials to fall off.

[0004] 2. For jet-type flames, localized heating causes cracking, resulting in large areas of fire-retardant coating peeling off.

[0005] 3. Most fire-retardant coatings have poor weather resistance and abrasion resistance. Summary of the Invention

[0006] The purpose of this invention is to overcome the problems existing in the prior art and provide a thick-film solvent-free epoxy fire-retardant coating and its application.

[0007] The technical problem solved by this invention is achieved by the following technical solution.

[0008] This invention provides a thick-film solvent-free epoxy fire-retardant coating, comprising component A and component B; Component A comprises the following components in parts by weight: 42.019-45.521 parts polyester-modified epoxy resin, 2.859-3.159 parts tall oil fatty acid, 1.368-1.512 parts glass fiber, 0.619-0.685 parts thixotropic thickener, 2.484-2.746 parts rheology modifier, and 46.085-50.937 parts flame retardant; Component B comprises the following components in parts by weight: 51.475-55.765 parts curing agent, 5.740-6.344 parts curing accelerator, 7.671-8.479 parts modifier, 1.534-1.696 parts glass fiber, 6.919-7.647 parts thixotropic thickener, 0.960-1.062 parts rheology modifier, and 21.158-23.386 parts melamine.

[0009] This invention provides an application of the above-mentioned coating in the fire protection of steel structures in hydrocarbon and jet fires.

[0010] The present invention has the following beneficial effects: The thick-film solvent-free epoxy fireproof coating provided by this invention has excellent adhesion, good wind resistance, water resistance, weather resistance, and durability, and there is no fire risk at the joints. Its performance is significantly better than that of traditional fireproof coatings. Detailed Implementation

[0011] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased commercially.

[0012] The following is a detailed description of a thick-film solvent-free epoxy fire-retardant coating and its application provided by an embodiment of the present invention.

[0013] In a first aspect, the present invention provides a thick-film solvent-free epoxy fire-retardant coating, comprising component A and component B; Component A comprises the following components in parts by weight: 42.019-45.521 parts polyester-modified epoxy resin, 2.859-3.159 parts tall oil fatty acid, 1.368-1.512 parts glass fiber, 0.619-0.685 parts thixotropic thickener, 2.484-2.746 parts rheology modifier, and 46.085-50.937 parts flame retardant; Component B comprises the following components in parts by weight: 51.475-55.765 parts curing agent, 5.740-6.344 parts curing accelerator, 7.671-8.479 parts modifier, 1.534-1.696 parts glass fiber, 6.919-7.647 parts thixotropic thickener, 0.960-1.062 parts rheology modifier, and 21.158-23.386 parts melamine.

[0014] This invention provides a thick-film solvent-free epoxy fire-retardant coating, comprising component A and component B, wherein component A comprises the following components in parts by weight: 42.019-45.521 parts of polyester-modified epoxy resin, 2.859-3.159 parts of tall oil fatty acid, 1.368-1.512 parts of glass fiber, 0.619-0.685 parts of thixotropic thickener, 2.484-2.746 parts of rheology modifier, and 46.085-50.937 parts of flame retardant. The combination of polyester-modified epoxy resin and tall oil fatty acid as a film-forming system improves the moldability of the coating. The addition of glass fiber significantly improves the tensile and impact resistance of the finished product. The added flame retardant provides flame retardancy, while appropriate amounts of rheology modifier and thixotropic thickener enhance the stability of the thick film during film formation. Component B comprises the following components in parts by weight: 51.475-55.765 parts curing agent, 5.740-6.344 parts curing accelerator, 7.671-8.479 parts modifier, 1.534-1.696 parts glass fiber, 6.919-7.647 parts thixotropic thickener, 0.960-1.062 parts rheology modifier, and 21.158-23.386 parts melamine. The curing agent and curing accelerator promote the curing of polyester-based epoxy resin, while the modifier acts as a catalyst for the epoxy resin and polyurethane in the coating process. The formation of a dense network structure in the layer improves the adhesion performance of the coating, strengthens the adhesion between the coating and the substrate, and enhances the anti-corrosion effect. In addition, the addition of glass fiber can significantly improve the tensile and impact resistance of the finished product. The added flame retardant melamine can play a flame retardant role, while appropriate amounts of rheology modifiers and thixotropic thickeners can improve the stability of high-thickness films during the film formation process. Furthermore, the addition of glass fiber and rheology modifiers to component B can make component B and component A have similar compositions, making it easier for them to fuse together during the mixing process without defects such as delamination and sedimentation.

[0015] As can be seen from the above, this invention solves the problem of the continuity of fire-retardant materials during the ignition process, as well as the problem of the expansion of local flames and jet fire affecting other parts, by using solvent-free epoxy intumescent fire-retardant coatings. By using solvent-free aluminum triphosphate modified epoxy ester resin as the film-forming substance, the fire-retardant coating improves its weather resistance and abrasion resistance, and has good chemical resistance.

[0016] In some alternative embodiments, the polyester-modified epoxy resin is selected from EPOXY JH0711RESIN manufactured by PPG Industries, and the tall oil fatty acid is selected from SYLFAT™ FA2 manufactured by Kraton Industries and / or WESTVACOL1ASE manufactured by MeadWestvaco Industries.

[0017] The solvent-free epoxy intumescent fire-retardant coatings provided above use a film-forming system composed of a mixture of polyester epoxy resin and tall oil fatty acid. In some embodiments, the polyester epoxy resin is selected as EPOXY JH0711 RESIN, a polyester epoxy ester resin manufactured by PPG Industries, Inc. PPG HEAVYDUTYMAINT-APP is a high-performance industrial coating resin with characteristics including: high solids content and low VOCs, helping to reduce environmental pollution and improve construction efficiency; excellent corrosion resistance and adhesion, suitable for heavy industrial environments such as ships, bridges, and chemical equipment; good mechanical strength and durability, able to withstand harsh weather and chemical erosion; and flexible application, applicable by spraying or brushing, and adaptable to different curing conditions. Tall oil fatty acid is a natural vegetable oil extracted from a byproduct of the paper industry, with characteristics including: low cost and renewable, sustainable as a natural raw material source; good wetting and dispersibility, improving coating leveling and substrate adhesion; and moderate weather resistance and chemical resistance, but requires blending with other resins to enhance performance. Combining polyester epoxy resin and tall oil fatty acid to form a film-forming system can give the coating good moldability, excellent adhesion between the coating and the substrate, and make it less prone to peeling and delamination, thus integrating it with the protected structure.

[0018] In some alternative embodiments, the flame retardant includes at least one of ammonium polyphosphate, ammonium pentaborate tetrahydrate, and zinc borate, preferably selected from ammonium polyphosphate, ammonium pentaborate tetrahydrate, and zinc borate in a mass ratio of 3.85-4.00:18.95-19.73:24.74-25.74.

[0019] The solvent-free epoxy intumescent fire-retardant coating provided by this invention contains one or more of ammonium polyphosphate, ammonium pentaborate tetrahydrate, and borate pentahydrate as a flame retardant. Ammonium polyphosphate is commonly used in fire protection and fire prevention, typically in aqueous solution form, suitable for extinguishing oil fires or as a fire retardant for wood and fabrics. Its main component is ammonium phosphate, which exhibits rapid charring and flame spread inhibition. Ammonium pentaborate is mainly used in fire-retardant wood, textiles, glass manufacturing, and telecommunications equipment, and can also be used as a flame-retardant additive. Zinc borate releases water of crystallization at temperatures exceeding 290°C, providing flame retardancy and smoke suppression. This product has a polymer-like refractive index, maintaining the translucency of materials, and is suitable for plastics, rubber, and other systems. In some embodiments of this invention, ammonium polyphosphate, ammonium pentaborate tetrahydrate, and zinc borate are used in combination. Through a synergistic effect, the flame-retardant performance is significantly improved, while potentially reducing the amount of any single flame retardant and optimizing the overall material performance. This combination achieves multiple flame-retardant mechanisms in both the gas and condensed phases, such as inhibiting combustion by capturing free radicals, forming an insulating char layer, or diluting combustible gases. Specifically, the combined flame retardants function as follows: ammonium phosphate can achieve an LOI of 31.8% and a UL94 V-0 rating; zinc borate achieves flame retardancy by forming a glassy protective layer and releasing water vapor; and ammonium pentaborate tetrahydrate exhibits a synergistic effect of boron and nitrogen, promoting the formation of a dense char layer. The synergistic effect of the combination, ammonium phosphate + zinc borate: synergistically enhances the char layer; APP provides an acid source and expansion structure; ZB promotes char layer densification and thermal stability. The combination increases the char residue by 30–50%, and the LOI can reach over 34%. Improved thermal stability: TGA shows that the thermal degradation initiation temperature of the combined system is increased by 50–80℃, and the char residue at 800℃ is significantly higher than that of the single component. Ammonium pentaborate tetrahydrate + ammonium phosphate: potential synergy; the boron-nitrogen system and the phosphorus-nitrogen system can form a multi-element synergistic charring network, improving the flame-retardant effect.

[0020] In some alternative embodiments, the glass fiber filament is a chopped glass fiber filament, preferably with a length of 0.5cm-1.5cm.

[0021] Adding glass fiber filaments to thick-film solvent-free epoxy fire-retardant coatings has the following effects: High Temperature Resistance: Fiberglass filaments possess excellent high temperature resistance, resisting heat radiation and flame attack in high-temperature environments. They maintain stable physical and chemical properties at high temperatures, preventing the spread of fire. High Strength: Fiberglass filaments have high strength and stiffness, providing structural strength and compressive strength. Using fiberglass filaments in fire-resistant materials increases the overall strength of the material, enhancing its durability and impact resistance. Lightweight: Compared to some traditional fire-resistant materials, fiberglass filaments have a lower density, allowing for lightweight design. This reduces the load and weight on buildings and structures. Corrosion Resistance: Fiberglass filaments exhibit excellent corrosion resistance, resisting the erosion of acids, alkalis, moisture, and some chemicals. This allows fire-resistant materials to maintain stability and reliability even in harsh environments.

[0022] In some alternative embodiments, the curing agent includes one or more of the polyamide curing agents VERSAMID 150, Huntsman Versamid 250, and Kukdo KD-560. VERSAMID 150 is a low-viscosity polyamide curing agent launched by Huntsman, which is formed by the condensation of dimer fatty acids and polyamines. Its core function is as a room temperature curing agent for epoxy resins, while also having key functions such as reducing system viscosity, improving toughness and chemical resistance, and enhancing adhesion.

[0023] In some optional embodiments, the curing accelerator includes one or more of 2,4,6-tris[(dimethylamino)methyl]phenol VERSAMINEEH 30, Evonik Ancamine K54, and Carnos DMP-30. VERSAMINEEH 30 is a tertiary amine curing accelerator / latent curing agent widely used in epoxy resin systems, possessing functions such as promoting curing, regulating reaction rate, and improving crosslinking network properties.

[0024] In some alternative embodiments, the modifier includes one or more of the following: bisphenol A ethoxylated compound MACOL98 B, Dow Tergitol 15-S-9, and Nippon Shokubai Newcol BA10.

[0025] In some alternative embodiments, the rheology modifier includes one or more of THIXATROL ST, Arkema CRAYVALLAC MT, and Kaysalor THIXCIN R. THIXATROL ST, developed by Deqian Company, is a rheology modifier primarily used in solvent-based coating systems (such as aliphatic and aromatic solvent systems). It improves freeze-thaw resistance, flowability, and gloss by adjusting the viscosity characteristics of the system, and also improves color development and storage stability, helping to prevent pigment sedimentation and enhance the uniformity of the dispersion system.

[0026] In some alternative embodiments, the thixotropic thickener includes one or more of ATTAGEL 50, Clariant Bentone 38, and Arkema Volclay SPV. ATTAGEL 50 is a thixotropic thickener manufactured by BASF, whose main component is attapulgite (a magnesium aluminum silicate hydrate). It thickens the system by forming a three-dimensional network structure, reducing viscosity under shear forces (e.g., good leveling properties during application) and resting viscosity (e.g., preventing sagging), thereby improving the coating's anti-settling and anti-sagging properties.

[0027] In some alternative implementations, it also includes: pigments.

[0028] As can be seen from the above, the solvent-free epoxy intumescent fire-retardant coating provided by this invention, during the flame contact process, maintains film formation and protects the integrity of the coating through the epoxy system in the low-temperature stage. When the temperature rises to a certain level, the glass fiber filaments melt at high temperatures to fulfill multiple functional requirements. Epoxy possesses special resistance to automobile exhaust, acid rain, and organic solvent splashes, ensuring effective protection time of 1100℃ × 120 minutes. The construction process is completed in one step, reducing construction costs and risks, such as the safety factors of long-term road closures during highway guardrail construction and other factors brought about by long construction cycles. Compared with traditional construction methods that require multiple different product systems, this significantly saves construction costs, reduces risks, and greatly improves the construction process. It does not contain volatile organic compounds, meeting current requirements for green and environmentally friendly coatings.

[0029] Secondly, the present invention provides an application of the above-mentioned thick-film solvent-free epoxy fire-retardant coating in the fire protection of steel structures in hydrocarbon and jet fires.

[0030] In some alternative implementations, the coating is used on offshore platforms—steel structural beams and columns, bulkheads and decks, highway bridge suspension cables and main cables, on-road facilities—pipeline works, storage tanks and containers, or oil refining facilities.

[0031] The present invention will be further described below with reference to embodiments.

[0032] The manufacturers and models of the raw materials used in the following examples and comparative examples are shown in the table below:

[0033] The fire-retardant coatings prepared in the examples and comparative examples were sprayed onto the surface of steel, and their application performance was tested as follows.

[0034] The compatibility test was conducted in accordance with GB14907-2023, the new standard for fire-retardant coatings. Artificial weathering resistance test: conducted according to Cycle A of GB / T 1865-2009, with samples collected after 4000 hours. Results are evaluated according to GB / T 1766. Adhesion test standard: GB / T 5210-2006 Paints and Varnishes - Pull-off test for adhesion. The testing standard for waterproofing rating is GB55030-2022 General Specification for Waterproofing of Building and Municipal Engineering.

[0035] Example 1 A thick-film solvent-free epoxy fire-retardant coating, comprising component A and component B, wherein component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN 43.77 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT 2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate borate FIREBRAKE ZB25.25 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.62 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 Laboratory and field verification showed that the fire-retardant coating formulated above achieved optimal performance in all aspects, with 100% integration with the protected structure, adhesion ≥5, waterproof rating IV, weather resistance over 4000 hours, and no impact on fire resistance at joints, indicating that the solution is feasible.

[0036] Example 2 Based on Example 1, the amount of epoxy ester resin HEAVY DUTY MAINT-AAP used was reduced by 2 percentage points, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN42.89 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT 2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 The pull-out adhesion of the fire-retardant coatings formulated above has decreased, and the overall viscosity and workability have decreased slightly, but this does not affect their use and application.

[0037] Laboratory and field verification showed that the performance in all aspects reached its optimal state, with 100% integration with the protected structure, adhesion ≥5, waterproof rating IV, weather resistance of over 4000 hours, and no impact on fire resistance at the joints, indicating that the solution is feasible.

[0038] Example 3 Based on Example 1, the amount of epoxy ester resin HEAVY DUTY MAINT-AAP used was increased by 2 percentage points, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN 44.65 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT 2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 The pull-out adhesion of the fire-retardant coatings formulated above did not change significantly, the overall viscosity decreased and the anti-sagging performance slightly declined, and the material cost increased, but it did not affect the use and construction.

[0039] Laboratory and field verification showed that the performance in all aspects reached its optimal state, with 100% integration with the protected structure, adhesion ≥5, waterproof rating IV, weather resistance of over 4000 hours, and no impact on fire resistance at the joints, indicating that the solution is feasible.

[0040] Example 4 Based on Example 1, the usage of flame retardant PHOS-CHEK P30, AMMONIUM PENTABORATE (TECHPOWDER), and AM_FIREBRAKE ZB is increased by 1 percentage point, or one of them is increased by 3 percentage points, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN43.87 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT 2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.81 Ammonium pentaborate tetrahydrate flame retardant 19.15 Flame retardant pentahydrate borate FIREBRAKE ZB24.98 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 The flame retardant effect of the above-formulated fire-retardant coatings remains largely unchanged, but the overall viscosity is reduced and the anti-sagging performance is slightly decreased, while the material cost increases.

[0041] Laboratory and field verification shows that the performance in all aspects can reach the optimal state, with 100% integration with the protected structure, adhesion ≥5, waterproof rating IV, weather resistance of more than 4000 hours, and no impact on fire resistance at the joints. The solution is feasible, but the viscosity needs to be adjusted appropriately during construction.

[0042] Example 5 Based on Example 1, the amount of polyamide curing agent VERSAMID 150 used was reduced by 3%, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN43.87 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15052.02 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.81 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A22.27 The viscosity and application performance of the fire-retardant coatings formulated above remain largely unchanged.

[0043] Laboratory and on-site verification showed that the solution achieved optimal performance in all aspects, 100% integration with the protected structure, adhesion ≥5, waterproof rating IV, weather resistance over 4000 hours, and fire resistance at the joints was unaffected, indicating that the solution is feasible.

[0044] Comparative Example 1 Based on Example 1, the amount of epoxy ester resin HEAVY DUTY MAINT-AAP used was reduced by 5 percentage points, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin HEAVY DUTY MAINT-AAP41.58 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate (TECH POWDER) 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 The pull-out adhesion of the fire-retardant coatings formulated above has decreased, and the overall viscosity and workability have also decreased, making them unsuitable for application and the proposed solution unfeasible.

[0045] Comparative Example 2 Based on Example 1, the amount of epoxy ester resin HEAVY DUTY MAINT-AAP used was increased by 5 percentage points, wherein: Polyester-modified epoxy resin HEAVY DUTY MAINT-AAP45.96 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT 2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate (TECH POWDER) 19.34 AM_FIREBRAKE ZB 25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.08 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A 22.27 The pull-out adhesion of the fire-retardant coatings formulated above did not change significantly, but the overall viscosity decreased and the anti-sagging performance deteriorated, resulting in increased material costs.

[0046] Laboratory and field verification showed that the epoxy resin content of the fire-retardant coating exceeded 5%, the viscosity was too low, which easily caused sagging, uneven film thickness, poor fire resistance, and the solution was not feasible.

[0047] Comparative Example 3 Based on Example 1, the usage of flame retardant PHOS-CHEK P30, AMMONIUM PENTABORATE (TECHPOWDER), and AM_FIREBRAKE ZB is increased by 2 percentage points, or one of them is increased by 6 percentage points.

[0048] Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN40.87 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.73 Flame retardant ammonium pentaborate tetrahydrate 18.95 Flame retardant pentahydrate FIREBRAKE ZB24.73 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15053.63 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.81 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A22.27 The flame-retardant effect of the above-formulated fire-retardant coatings remains largely unchanged, but the overall viscosity decreases and the anti-sagging performance deteriorates, while the material cost increases.

[0049] Laboratory and field verification showed that the fire-retardant coating had too high viscosity, making it difficult to apply, resulting in uneven film thickness and little change in fire-retardant performance, thus rendering the solution unfeasible.

[0050] Comparative Example 4 Based on Example 1, the amount of amine curing agent VERSAMID 150 used was reduced by 5%, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN43.87 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P303.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15050.95 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.81 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A22.27 Laboratory and field verification revealed that the fire-retardant coating had excessively high viscosity, a long cross-linking reaction time, a soft film, and poor anti-sagging ability, making the proposed solution unfeasible.

[0051] Comparative Example 5 Based on Example 1, the amount of polyamide curing agent VERSAMID 150 used was increased by 5 percentage points, wherein: Component A comprises the following components in parts by weight: Polyester-modified epoxy resin EPOXY JH0711 RESIN43.87 Tall oil fatty acid TALLOILFATTYAC / SYLFFA-2 / WESTVACOL1A SE3.01 3156 Chopped Strand 1.44 Thixotropic thickener ATTAGEL 500.65 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT2.62 Flame retardant ammonium polyphosphate PHOS-CHEK P309.93 Flame retardant ammonium pentaborate tetrahydrate 19.34 Flame retardant pentahydrate FIREBRAKE ZB25.24 Component B comprises the following components in parts by weight: Polyamide resin VERSAMID 15056.31 2,4,6-Tris[(dimethylamino)methyl]phenol VERSAMINE EH 306.04 Bisphenol A ethoxylated compound MACOL 98 B 8.08 Carbon Black LAMP 101 POWDER 0.81 3156 Chopped Strand 1.62 Thixotropic thickener ATTAGEL 507.28 Hydrogenated castor oil THIXATROL ST / CRAYVALLAC MT1.01 Melamine, Tech. Sort A22.27 Laboratory and field verification showed that the viscosity of the fire-retardant coating did not change significantly, the crosslinking reaction time was not significant, the paint film was intact, the anti-sagging ability changed greatly, sagging was serious, the fire resistance was poor, the construction and anti-corrosion performance and waterproof performance were acceptable, etc., so the solution was not feasible.

[0052] Compared with traditional coatings, the thick-film solvent-free epoxy fire-retardant coating provided by this invention has the following advantages: Good adhesion: The coating and substrate have excellent adhesion, are not easy to peel or delaminate, and integrate well with the protected structure; Good wind resistance: It will not peel off due to wind factors; Good water resistance: It has excellent anti-corrosion performance, extremely low water absorption, and excellent water resistance; Good weather resistance: It can withstand very humid river, lake and sea environments and even high salt corrosion, and can withstand various harsh scenarios such as ultraviolet radiation, alternating dry and wet heat, sudden temperature changes, and chemical corrosion environments; Good durability: The durability can reach the service life while the fire resistance performance decay is controlled within a very low limit, such as only 10-15% decay, and there are no fire resistance problems at the joints.

[0053] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A thick-film solvent-free epoxy fire-retardant coating, characterized in that, Thick-film solvent-free epoxy fire-retardant coating, including component A and component B; Component A comprises the following components in parts by weight: 42.019-45.521 parts polyester-modified epoxy resin, 2.859-3.159 parts tall oil fatty acid, 1.368-1.512 parts glass fiber, 0.619-0.685 parts thixotropic thickener, 2.484-2.746 parts rheology modifier, and 46.085-50.937 parts flame retardant; Component B comprises the following components in parts by weight: 51.475-55.765 parts curing agent, 5.740-6.344 parts curing accelerator, 7.671-8.479 parts modifier, 1.534-1.696 parts glass fiber, 6.919-7.647 parts thixotropic thickener, 0.960-1.062 parts rheology modifier, and 21.158-23.386 parts melamine.

2. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The polyester-modified epoxy resin was selected from EPOXY JH0711 RESIN manufactured by PPG, and the tall oil fatty acid was selected from SYLFAT™ FA2 manufactured by Kraton and / or WESTVACOL1ASE manufactured by MeadWestvaco.

3. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The flame retardant includes at least two of ammonium polyphosphate, ammonium pentaborate tetrahydrate, and zinc borate, and the quantity is not less than the total quantity. Preferably, the flame retardant is selected from ammonium polyphosphate, ammonium pentaborate tetrahydrate, and zinc borate in a mass ratio of 3.926:19.34:25.

245.

4. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The glass fiber filament is a chopped glass fiber filament, preferably with a length of 0.5cm-1cm.

5. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The curing agent includes one or more of the following polyamide curing agents: VERSAMID 150, Huntsman Versamid 250, and Kukdo KD-560; the curing accelerator includes one or more of the following: 2,4,6-tris[(dimethylamino)methyl]phenol VERSAMINEEH 30, Evonik Ancamine K54, and Kanos DMP-30.

6. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The modifier includes one or more of the following: bisphenol A ethoxylated compound MACOL 98B, Dow Tergitol 15-S-9, and Nippon Shokubai Newcol BA10.

7. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, The rheology modifiers include one or more of THIXATROL ST, Arkema CRAYVALLAC MT, and Kaysalor THIXCIN R, and the thixotropic thickeners include one or more of ATTAGEL 50, Clariant Bentone 38, and Arkema VOLCLAY SPV.

8. The thick-film solvent-free epoxy fire-retardant coating according to claim 1, characterized in that, Also includes: pigment.

9. The application of the thick-film solvent-free epoxy fire-retardant coating according to any one of claims 1-8 in the fire protection of steel structures in hydrocarbon and jet fires.

10. The application according to claim 9, characterized in that, The coating is used on offshore platforms – steel structural beams and columns, bulkheads and decks, highway bridge suspension cables and main cables, on-road facilities – pipeline works, storage tanks and containers, or oil refining equipment and facilities.

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