Intumescent coating compositions and methods of making and using the same

Abstract

An intumescent coating composition comprising a resin system, the resin system comprising: a reaction product of an epoxy component and a monofunctional carboxylic acid; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component, wherein the composition is curable by free radical polymerization. A method of making an intumescent coating composition comprising: mixing an epoxy component and a monofunctional carboxylic acid to form a reaction product by ring opening reaction of the epoxy component; and mixing an intumescent component with the reaction product and a monomer mixture. A method of coating a substrate with an intumescent coating comprising: mixing a liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition; applying the activated coating composition to a substrate; and curing the activated coating composition under ambient conditions to a solid state to form an intumescent coating.

Description

Cross-references to related applications

[0001] This application claims the benefits of U.S. Provisional Application No. 63 / 564,157, filed March 12, 2024, and U.S. Provisional Application No. 63 / 674,521, filed July 23, 2024, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0002] This disclosure relates to intumescent coating compositions and intumescent coatings made therefrom. This disclosure also relates to methods for preparing and using intumescent coating compositions. Background Technology

[0003] Buildings and structures can be protected from the destructive effects of fire by using various fire-resistant systems, including mineral insulation materials, cement sprays, intumescent coatings, and self-supporting intumescent sheets. Intumescent materials expand when heated and can be used to insulate materials and structures from heat, slowing the spread of fire by blocking openings that could allow it to spread. During a fire, intumescent coatings undergo a series of reactions to produce insulating char, which slows heat transfer to the underlying structure. This delays the time it takes for the structure to lose its load-bearing strength. Some intumescent materials produce lightweight char due to the heating of their components, such as carbon-containing binders. Some intumescent materials, such as those containing sodium silicate or graphite, produce hard char. Intumescent materials may also include flame retardants or compounds, such as hydrates, that have a cooling effect upon heating and decomposition.

[0004] Intumescent coatings can be used on a wide variety of materials, including metals (such as steel, aluminum and other metals), concrete, wood, plastics and combinations thereof.

[0005] Liquid-expanding coating compositions can be used as paints to cover surfaces. Many of these existing liquid-expanding coating compositions result in thicker coatings and may produce coating appearance defects such as ripples or other uneven textures.

[0006] Further improvements are needed to the liquid-expanding coating composition. Summary of the Invention

[0007] An intumescent coating composition comprising a resin system including a reaction product of: an epoxy component and a monofunctional carboxylic acid with a chain length of 6 to 30 carbon atoms; a monomer mixture including at least one olefinically unsaturated monomer; and an intumescent component, wherein the composition can be cured by free radical polymerization. The epoxy component and the monofunctional carboxylic acid are soluble in the monomer mixture. The reaction product is soluble in the monomer mixture. The epoxy component may include an epoxy resin containing two or more epoxy groups. The epoxy component may include an epoxy resin that is solid at a temperature of 20°C. The intumescent coating composition may be free of solvents other than the monomer mixture. The monomer mixture may comprise 30% to 90% by weight of the resin system. The reaction product may comprise 2% to 60% by weight of the intumescent coating composition.

[0008] The intumescent coating composition may be a two-part composition, wherein the first part comprises a reaction product, a monomer mixture, and an intumescent component, and the second part comprises a peroxide initiator. The first part may also comprise an amine promoter. In some embodiments, the intumescent coating composition may be provided as a three-part composition.

[0009] The expansion components may include an acid source, a carbon source, and a gas source that provides expansion gases during thermal decomposition.

[0010] A method for preparing an intumescent coating composition includes: mixing an epoxy component and a monofunctional carboxylic acid to form a reaction product through a ring-opening reaction of the epoxy component; and preparing the coating composition by mixing the intumescent component with the reaction product and a monomer mixture comprising at least one olefinically unsaturated monomer. The method may include mixing an epoxide ring-opening catalyst with the epoxy component and the monofunctional carboxylic acid.

[0011] A method for coating a substrate with an intumescent coating includes: mixing a liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition; applying the activated coating composition to the substrate; and curing the activated coating composition into a solid state under ambient conditions to form an intumescent coating. The liquid intumescent coating composition can be cured by free radical polymerization. The liquid intumescent coating composition can be cured by exposure to air at ambient temperature. The initiator may include an organic peroxide. The activated coating composition can be cured at 25°C or lower for 60 minutes or less. During curing, the volatile components lost through evaporation in the coating composition may be less than 5% by weight. The cured intumescent coating has a Shore D hardness of 45 to 90, measured 24 hours after application.

[0012] A kit for applying an intumescent coating to a substrate may include a first part comprising a resin system and a second part comprising a peroxide initiator and an amine promoter. The resin system comprises an epoxy component and a reaction product of a monofunctional carboxylic acid with a chain length of 6 to 30 carbons; the monomer mixture comprises at least one olefinically unsaturated monomer; and the intumescent component. Attached Figure Description

[0013] Figure 1 This is a TGA image of the sample prepared in Example 14 according to one implementation scheme.

[0014] Figures 2A-2D This is a TGA image of the sample prepared in Example 15 according to one implementation scheme.

[0015] definition

[0016] Unless otherwise stated, all scientific and technical terms used herein have their common meaning in the art. The definitions provided herein are for ease of understanding of certain terms used frequently herein and are not intended to limit the scope of this disclosure.

[0017] Unless otherwise specified, the terms "polymer" and "polymeric material" include, but are not limited to, organic homopolymers, copolymers such as, for example, block, graft, random and syndiotactic copolymers, terpolymers, and their blends and modifications. Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible geometries of the material. These geometries include, but are not limited to, isotactic, syndiotactic, and random symmetry.

[0018] The term "organic group" is used herein to mean a hydrocarbon group (having optional elements other than carbon and hydrogen, such as oxygen, nitrogen, sulfur, and silicon), which is classified as an aliphatic group, a cyclic group, or a combination of aliphatic and cyclic groups (e.g., alkylaryl groups and aralkyl groups). The term "aliphatic group" means a saturated or unsaturated straight-chain or branched hydrocarbon group. For example, this term is used to cover alkyl groups, alkenyl groups, and alkynyl groups. The term "alkyl group" means a saturated straight-chain or branched hydrocarbon group, including, for example, methyl, ethyl, isopropyl, tert-butyl, heptyl, dodecyl, octadecyl, pentyl, 2-ethylhexyl, etc. Unless otherwise specified, alkyl groups typically contain 1-30 carbon atoms. In some embodiments, alkyl groups contain 4 to 30 carbon atoms, 6 to 30 carbon atoms, or 6 to 26 carbon atoms. The term "alkenyl group" means an unsaturated, straight-chain or branched hydrocarbon group having one or more carbon-carbon double bonds, such as a vinyl group. The term "alkynyl group" refers to an unsaturated, straight-chain, or branched hydrocarbon group having one or more carbon-carbon triple bonds. The term "cyclic group" refers to a closed-ring hydrocarbon group, which is classified as an alicyclic, aromatic, or heterocyclic group. The term "alicyclic group" refers to cyclic hydrocarbon groups whose properties resemble those of alicyclic groups. The terms "aromatic group" or "aryl group" refer to mononuclear or polynuclear aromatic hydrocarbon groups. The term "heterocyclic group" refers to a closed-ring hydrocarbon where one or more atoms in the ring are elements other than carbon (e.g., nitrogen, oxygen, sulfur, etc.). Groups that may be the same or different are referred to as something "independently".

[0019] The term "alkylation" is used in this disclosure to describe a compound that reacts to replace a hydrogen atom or a negatively charged part of the compound with an alkyl group, such that the alkyl group is covalently bonded to the compound.

[0020] As used herein, the term “substantially” has the same meaning as “significantly” and can be understood to modify the term following it by at least about 90%, at least about 95%, or at least about 98%. The term “substantially free” for a particular compound means that the compositions of the present invention contain less than 1,000 parts per million (ppm) of the compound. In the context of the foregoing phrases, the compositions of the present invention contain less than the amounts of the compound described above, whether the compound is present in an unreacted form or has reacted with one or more other materials.

[0021] The term “substantially not” as used in this article has the same meaning as “not significant” and can be understood to have the opposite meaning of “substantially”, i.e., modifying the term following it with no more than 25%, no more than 10%, no more than 5%, or no more than 2%.

[0022] The term “about” is used herein in conjunction with numerical values ​​to include normal variation in measurements as would be expected by those skilled in the art, and is understood to have the same meaning as “approximately” and to cover typical error limits, such as ±5% of the value.

[0023] Terms such as “a”, “an” and “the” are not intended to refer only to singular entities, but rather to include general categories whose specific examples can be used to illustrate them.

[0024] The terms “an,” “a,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one” and “including at least one” following the list refer to any item in the list and any combination of two or more items in the list.

[0025] As used herein, unless otherwise expressly stated in the text, the term "or" is generally used in its conventional meaning, including "and / or". The term "and / or" means one or all of the listed elements or a combination of any two or more of the listed elements.

[0026] A range of values ​​listed by endpoints includes all values ​​contained within that range (for example, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc., or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). When the range of values ​​is "at most" or "at least" a specific value, that value is included in the range.

[0027] As used herein, terms such as “have / having,” “include / including,” and “comprise / comprising” are used in their open-ended sense and generally mean “including but not limited to.” It should be understood that phrases such as “consistently composed of,” “comprises from,” etc., fall under the category of “comprising.” As used herein, “consistently composed of” when referring to compositions, products, methods, etc., means that the components of the composition, product, method, etc., are limited to the listed components and any other components that do not materially affect the essential and novel characteristics of the composition, product, method, etc.

[0028] The terms "preferred" and "ideally" refer to embodiments that provide certain beneficial effects under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are unavailable, and is not intended to exclude other embodiments from the scope of this disclosure (including the claims).

[0029] Any orientations mentioned herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations, are described herein with reference to the accompanying drawings for clarity and do not limit the actual device or system or the use of such a device or system. Devices or systems as described herein can be used in multiple orientations and directions. Detailed Implementation

[0030] This disclosure relates to intumescent coating compositions and intumescent coatings made therefrom. This disclosure also relates to methods for preparing and using intumescent coating compositions.

[0031] It is desirable to provide a solvent-free intumescent coating composition that can protect structures during a fire. It is also desirable to provide an intumescent coating composition that can be applied as a thinner coating layer compared to existing compositions. Furthermore, it is desirable to provide an intumescent coating composition that can be polymerized in air via free radical polymerization.

[0032] An intumescent coating composition can be applied to a substrate and cured to form an intumescent coating. The term "intumescent coating composition" is used herein to refer to the liquid composition prior to curing, and the term "intumescent coating" is used to refer to the coating after curing. The intumescent coating composition may be provided in two or more parts, which may be combined prior to application.

[0033] According to one embodiment, the intumescent coating composition of this disclosure comprises an adduct or a reactant that generates an adduct. When applied to a substrate, the adduct migrates to the surface of the coating, forming a passivation layer beneath which monomers react via free radical polymerization. The passivation layer allows free radical polymerization to proceed without oxygen inhibition. The intumescent coating formed by the intumescent coating composition of this disclosure is thinner than coatings formed by existing intumescent coating compositions. The intumescent coating formed by the intumescent coating composition of this disclosure has equivalent or improved fire resistance performance compared to existing products. The intumescent coating formed by the intumescent coating composition of this disclosure has equivalent or improved resistance to the harmful effects of water exposure compared to existing products.

[0034] Intumescent coating compositions typically comprise an intumescent component and a resin system. The resin system comprises a mixture of monomers, an epoxy component, and a monofunctional carboxylic acid, and / or the reaction product of the epoxy component and the monofunctional carboxylic acid. The monomers in a liquid intumescent coating composition may be used as reactive diluents. That is, other components, including the epoxy component, the monofunctional carboxylic acid, and / or the reaction product of the epoxy component and the monofunctional carboxylic acid, are soluble in the monomers. Liquid intumescent coating compositions may contain no or substantially no solvents other than the monomers. That is, liquid intumescent coating compositions may contain no or substantially no solvents that do not polymerize and become part of the coating. Liquid intumescent coating compositions may contain no or substantially no solvents that will evaporate during curing. Liquid intumescent coating compositions may be referred to as solvent-free. As used herein, the term "solvent-free" means the absence of solvents other than reactive diluents.

[0035] Intumescent coating compositions and coatings comprise one or more intumescent components. Examples of intumescent components include acid sources, carbon sources, gas sources, and combinations thereof. Intumescent coating compositions and coatings may comprise at least one of each of acid sources, carbon sources, and gas sources.

[0036] A gas source can provide expanding gases during thermal decomposition. Such gas sources are sometimes referred to as "foaming agents." The gas causes the carbon produced by the expanding coating to expand, creating a multicellular foam that insulates the underlying structure. The volume of the foam can be many times the volume of the coating before heating. For example, the volume of the coating (e.g., foam) after heating (e.g., the expansion volume) can be 2 or more, 5 or more, 8 or more, 10 or more, or 20 or more times the volume of the coating before heating.

[0037] Examples of suitable gas sources include nitrogen-containing materials, carbon dioxide-releasing materials, and water vapor-releasing materials. Intumescent coating compositions may include any one or any combination of two or more of the following suitable gas sources. Suitable nitrogen-containing materials include, for example, melamine, phosphates (e.g., ammonium polyphosphate, ammonium polyphosphate, melamine phosphate, magnesium sulfate, boric acid, and ammonium sulfate, and combinations of two or more thereof), guanidine, hydroxymethyl melamine, hexamethoxymethyl melamine, urea, dimethylurea, melamine pyrophosphate, dicyandiamide, guanidinyl urea phosphate, glycine, etc., and combinations of two or more thereof. In some embodiments, the gas source is or includes melamine. In some embodiments, the gas source is or includes phosphates. In some embodiments, the gas source includes melamine and phosphates. Suitable carbon dioxide-releasing materials include, for example, alkaline earth metal carbonates, such as calcium carbonate and magnesium carbonate. Suitable water vapor-releasing materials include, for example, calcium hydroxide, magnesium dihydroxyl, and aluminum trihydroxyl, and combinations of two or more thereof. Another compound that can be used as an intumescent material is boric acid and its derivatives.

[0038] Intumescent coating compositions and intumescent coatings may contain a carbon source. The carbon source forms carbonaceous char during a fire. Preferably, the intumescent coating forms a char layer during a fire, and the char layer adheres to the underlying substrate without cracking.

[0039] Examples of suitable carbon sources include polyhydroxy compounds such as pentaerythritol, dipentaerythritol, glycerol, oligoglycerol, xylitol, mannitol, sorbitol, and polymers such as polyamides, polycarbonates, polyurethanes, and combinations of two or more of them.

[0040] Intumescent coating compositions and intumescent coatings may contain an acid source. Examples of suitable acid sources include ammonium phosphate, ammonium polyphosphate, diammonium diphosphate, diammonium pentaborate, phosphoric acid generating materials, boric acid, metal or organoborates, and combinations of two or more of them.

[0041] The one or more expanding components may be present in the expanding coating composition at a concentration that produces the desired expanding properties. This amount may vary depending on the specific expanding component used. In some embodiments, the one or more expanding components may be present in the expanding coating composition at a concentration of 1% or higher, 5% or higher, 10% or higher, 15% or higher, 20% or higher, 25% or higher, 30% or higher, 35% or higher, 40% or higher, 45% or higher, or 50% or higher. In some embodiments, the one or more expanding components may be present in the expanding coating composition at a concentration of 60% or lower, 50% or lower, 40% or lower, 35% or lower, 30% or lower, 25% or lower, 20% or lower, 15% or lower, 10% or lower, or 5% or lower. In some embodiments, the one or more intumescent components may be present in the intumescent coating composition at concentrations of 1% to 60% by weight, 5% to 50% by weight, 10% to 40% by weight, 15% to 35% by weight, or 20% to 30% by weight.

[0042] The intumescent coating composition comprises a resin system including a monomer mixture, an epoxy component, and a monofunctional carboxylic acid and / or a reaction product of the epoxy component and the monofunctional carboxylic acid. According to one embodiment, the epoxy component and the monofunctional carboxylic acid are soluble in the monomer mixture. The epoxy component and the monofunctional carboxylic acid react to form the reaction product. The reaction product of the epoxy component and the monofunctional carboxylic acid may also be soluble and / or already dissolved in the monomer mixture.

[0043] According to one embodiment, when an intumescent coating composition is applied to a substrate, the reaction products (e.g., adducts) of the epoxy component and monofunctional carboxylic acids migrate to the surface of the coating, forming a passivation layer. The monomers can then react via free radical polymerization beneath the passivation layer.

[0044] The epoxy component may include epoxy resins having two or more epoxy groups. The epoxy component may include epoxy resins that are solid at ambient temperature. For example, the epoxy component may include epoxy resins that are solid at temperatures below 30°C, 25°C, or about 20°C. The epoxy component may include epoxy resins with a glass transition temperature of 20°C or higher, 25°C or higher, or 30°C or higher. The epoxy component may include epoxy resins with a molecular weight of 500 or greater, 800 or greater, 1000 or greater, 1500 or greater, 1800 or greater, or 2000 or greater. The molecular weight of the epoxy resin may be 5000 or less, 4600 or less, 4000 or less, 3500 or less, 3000 or less, or 2500 or less. The molecular weight of epoxy resins can range from 500 to 5000, 800 to 4600, 1000 to 4000, 1500 to 3000, or 1800 to 2500.

[0045] Examples of suitable epoxy resins include butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl ether, multifunctional epoxy resins having a glycidyl amino group derived from m-phenylenediamine, and epoxy resins having a glycidyl amino group derived from 1,3-bis(aminomethyl) Multifunctional epoxy resins containing glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins containing glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins containing glycidyloxy groups derived from phenol novolac, multifunctional epoxy resins containing two or more glycidyloxy groups derived from resorcinol, and combinations of two or more of these. In some embodiments, the epoxy component comprises an epoxy resin comprising a multifunctional epoxy resin having glycidyl groups derived from bisphenol A, a multifunctional epoxy resin having glycidyl groups derived from bisphenol F, a multifunctional epoxy resin having glycidyl groups derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of these. In some embodiments, the epoxy component comprises a multifunctional epoxy resin having glycidyl groups derived from bisphenol A.

[0046] The epoxy component can be present in the intumescent coating composition at a concentration that produces the desired coating properties. This amount can vary based on the specific epoxy resin used. The amount can also vary based on the amount of carboxylic acid intended to react with the epoxy component. The amount can also vary based on the total amount of resin in the composition. The intumescent coating composition can be provided as a two-part composition. The concentration of the epoxy component can be expressed as the concentration in the first part comprising the resin system. In some embodiments, the epoxy component can be present in the intumescent coating composition at concentrations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, or 50% or more. In some embodiments, the epoxy component may be present in the intumescent coating composition at a concentration of 60% by weight or less, 50% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less. In some embodiments, the epoxy component may be present in the intumescent coating composition at a concentration of 2% to 60% by weight, 5% to 50% by weight, 10% to 40% by weight, 15% to 35% by weight, or 20% to 30% by weight.

[0047] Monofunctional carboxylic acids can have a chain length of 4 or more, 6 or more, 8 or more, or 10 or more carbons. Monofunctional carboxylic acids can have a chain length of 36 or fewer, 32 or fewer, 30 or fewer, 28 or fewer, 26 or fewer, 24 or fewer, 22 or fewer, or 20 or fewer carbons. Monofunctional carboxylic acids can have a chain length of 4 to 36 carbons, 6 to 30 carbons, or 8 to 22 carbons.

[0048] Any suitable monofunctional carboxylic acid can be used. According to one embodiment, the monofunctional carboxylic acid is soluble in the monomer mixture. The monofunctional carboxylic acid can be straight-chain, branched, or cyclic. The monofunctional carboxylic acid can be a saturated carboxylic acid. The monofunctional carboxylic acid may include substituents along the carbon chain, such as substituted nitrogen, sulfur, or oxygen atoms. The monofunctional carboxylic acid may include additional functional groups, provided that such additional functional groups do not interfere with the reaction between the epoxide component and the monofunctional carboxylic acid. The monofunctional carboxylic acid typically has the formula R-COOH, where R is an organic group. Exemplary monofunctional carboxylic acids include butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and lauric acid (CH3(CH2)2COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), octadecadienoic acid (linoleic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH, etc.

[0049] Monofunctional carboxylic acids can be present in the intumescent coating composition at a concentration that produces the desired coating properties. This amount can vary based on the monofunctional carboxylic acid used. This amount can also vary based on the amount of epoxy component intended to react with the monofunctional carboxylic acid. This amount can also vary based on the total amount of resin in the composition. The amount of monofunctional carboxylic acid (by weight) will vary according to the molecular weight of the acid. The intumescent coating composition can be provided as a two-part composition. The concentration of the monofunctional carboxylic acid can be expressed as the concentration in the first part comprising the resin system. In some embodiments, the monofunctional carboxylic acid can be present in the intumescent coating composition at a concentration of 1% or higher, 2% or higher, 3% or higher, 4% or higher, 5% or higher, 6% or higher, 7% or higher, 8% or higher, or 9% or higher. In some embodiments, the monofunctional carboxylic acid may be present in the intumescent coating composition at concentrations of 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, or 2% by weight or less. In some embodiments, the monofunctional carboxylic acid may be present in the intumescent coating composition at concentrations of 1% to 10% by weight, 2% to 9% by weight, 3% to 8% by weight, 4% to 7% by weight, or 5% to 6% by weight.

[0050] The epoxy component reacts with a monofunctional carboxylic acid to form a long-chain side-chain ester. The reaction can be accelerated by using a catalyst that opens the epoxy ring of the epoxy component. The relative amounts of the epoxy component and the monofunctional carboxylic acid can be chosen such that the molar amounts of the reactive groups are equal or substantially equal. For example, the ratio of epoxy groups to acid groups can be 0.5:1 to 1:0.5, 0.75:1 to 1:0.75, 0.8:1 to 1:0.8, 0.9:1 to 1:0.9, or about 1:1. In some embodiments, the epoxy compound is a diepoxide containing two epoxy groups per molecule. In such embodiments, the molar ratio of the epoxy compound to the monofunctional carboxylic acid can be about 1:2, or 0.5:2 to 1.5:2, 0.75:2 to 1.25:2, 0.8:2 to 1.2:2, or 0.9:2 to 1.1:2.

[0051] The reaction products of epoxy components and monofunctional carboxylic acids can be present in intumescent coating compositions at concentrations that produce the desired coating properties.

[0052] The epoxy component and the monofunctional carboxylic acid may be present in the intumescent coating composition at concentrations that produce reaction products having concentrations of 2% or higher, 5% or higher, 10% or higher, 15% or higher, 20% or higher, 25% or higher, or 30% or higher. The epoxy component and the monofunctional carboxylic acid may also be present in the intumescent coating composition at concentrations that produce reaction products having concentrations of 60% or lower, 50% or lower, 40% or lower, 35% or lower, 30% or lower, 25% or lower, or 20% or lower. The reaction product may be present in the intumescent coating composition at concentrations of 2% to 60% by weight, 5% to 50% by weight, 10% to 50% by weight, 12% to 50% by weight, 15% to 50% by weight, 20% to 50% by weight, 25% to 50% by weight, 10% to 40% by weight, 12% to 40% by weight, 15% to 40% by weight, 20% to 40% by weight, 10% to 35% by weight, 12% to 35% by weight, 15% to 35% by weight, or 20% to 35% by weight. The concentration of the reaction product may be expressed as the concentration in the first part comprising the resin system.

[0053] The resin system comprises a monomer mixture. The monomer mixture can act as a reactive solvent. The reactive solvent dissolves at least some of the other components of the resin system, such as the epoxy component and the monofunctional carboxylic acid. The monomer mixture may contain one or more polymerizable monomers. Examples of suitable monomers in the monomer mixture include olefinically unsaturated monomers. olefinically unsaturated monomers may include acrylic acid, methacrylic acid, and their reaction products (e.g., esters). Examples of suitable (meth)acrylate monomers include methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, and combinations thereof.

[0054] The monomers may be selected from suitable monomers that, when mixed together, constitute a liquid mixture at room temperature. The monomer mixture may contain olefinically unsaturated components that can be polymerized by peroxides.

[0055] The monomer mixture may constitute 20% or more, 30% or more, 40% or more, or 50% or more of the resin system. The monomer mixture may constitute 90% or less, 80% or less, 70% or less, or 60% or less of the resin system. The monomer mixture may constitute 20% to 90%, 30% to 90%, or 40% to 80% of the resin system.

[0056] Intumescent coating compositions may contain no or substantially no solvents other than monomer mixtures. Intumescent coating compositions may contain no or substantially no non-polymerizable solvents.

[0057] The monomer mixture can be mixed with an initiator (such as a peroxide) to initiate polymerization. Because the peroxide typically induces polymerization upon being mixed into the monomer mixture, it can be provided as a separate component of the intumescent coating composition. That is, the intumescent coating composition can be provided as a two-part composition, wherein the first part comprises a monomer mixture (e.g., as part of a resin system), and the second part comprises a peroxide. The first part may also comprise an epoxy component and a monofunctional carboxylic acid, or a reaction product of an epoxy component and a monofunctional carboxylic acid. The first part may also comprise an intumescent component, as well as any optional additional polymer components and additives. The first part may also comprise a accelerator. To use the two-part composition, the first and second parts can be mixed just before application or at the spray gun of a multi-component spraying unit. In some embodiments, the intumescent coating composition can be provided as a three-part composition. In the three-part composition, the first and second parts are similar in that they comprise an epoxy component and a monofunctional carboxylic acid, or a reaction product of an epoxy component and a monofunctional carboxylic acid; an intumescent component, as well as any optional additional polymer components and additives. The first part also comprises a accelerator, while the second part does not. The third part comprises a peroxide. In order to use the three-part composition, the second and third parts can be mixed before application, and the mixture and the first part are mixed at the spray gun of the multi-component spraying unit, or just before application.

[0058] Suitable peroxides include any compound having a structure containing the ROOR structure (e.g., metal peroxides), organic peroxide compounds having the COOC or COOH bond (e.g., dicumyl peroxide, hydrogen peroxide), and combinations of two or more of these. The initiator (comprising two parts by weight of the total intumescent coating composition) may be contained in the intumescent coating composition at concentrations of 0.05% or higher, 0.1% or higher, 0.5% or higher, 1% or higher, 2% or higher, 3% or higher, 4% or higher, 5% or higher, 6% or higher, or 7% or higher. The initiator may be contained in the intumescent coating composition at concentrations of 8% or lower, 7% or lower, 6% or lower, 5% or lower, 4% or lower, 3% or lower, 2% or lower, 1% or lower, 0.5% or lower, or 0.1% or lower. The initiator may be included in the intumescent coating composition at concentrations of 0.05% to 8% by weight, 0.1% to 7% by weight, 0.5% to 6.5% by weight, or 1% to 6% by weight.

[0059] Polymerization reactions can be accelerated by using accelerators. Accelerators can be amine accelerators. Suitable amine accelerators include p-toluidine ethoxylates (N,N-dimethylaniline), N,N-dialkyl-p-toluidine compounds (e.g., N,N-dimethyl-p-toluidine, N,N-bis-(2-hydroxypropyl)-p-toluidine, N,N-methyl-n-hydroxyethyl-p-toluidine), and combinations of two or more of these. Based on the amount of peroxide, amine accelerators can be contained at concentrations of 0% or higher, 1% or higher, 2% or higher, 3% or higher, 4% or higher, 5% or higher, 6% or higher, 7% or higher, 8% or higher, or 9% or higher. Based on the amount of peroxide, amine accelerators may be contained at concentrations of 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less. Based on the amount of peroxide, amine accelerators may be contained at concentrations of 0% to 10% by weight, 1% to 9% by weight, 2% to 8% by weight, 3% to 7% by weight, or 4% to 6% by weight.

[0060] The resin system may also include polymers. Polymers may include at least one of homopolymers, copolymers, or terpolymers of methacrylic resins. Polymers may be or include (meth)acrylate copolymers. Polymers may be reaction products of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate. Polymers may contain reaction products of one or more dienes with at least one of the following: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl tert-carbonate. Polymers may be or include solid thermoplastic resins.

[0061] The concentration of the polymer can be expressed as the concentration in the first part comprising the resin system. The polymer may comprise up to 50% by weight, up to 40% by weight, up to 30% by weight, up to 20% by weight, or up to 10% by weight of the resin system. The polymer may comprise 10% by weight or more, 20% by weight or more, 30% by weight or more, or 40% by weight or more of the resin system. The polymer may comprise 10% by weight to 50% by weight, 15% by weight to 45% by weight, 20% by weight to 40% by weight, or 25% by weight to 35% by weight of the resin system.

[0062] The intumescent coating composition may also contain an epoxy ring-opening catalyst. Any suitable catalyst can be used. Examples of suitable catalysts include tertiary amines such as pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, etc.; quaternary ammonium salts, quaternary phosphorus salts; dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide; imidazoles and their derivatives, such as 1-methylimidazolium, 1,2-dimethylimidazolium, 2-methylimidazolium, 2-ethylimidazolium, 1-ethylimidazolium, 1,3-disubstituted imidazolium salts, etc.; N - Heterocyclic carbenes or potential N-heterocyclic carbenes, such as 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, etc.; Lewis acids, such as halides of Al, B, Be, Ti, Zr, Zn, Sn, Fe(III), etc., and metal alkoxides, metal chelates, and metal oxides, such as zinc acetylacetone, zinc octanoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane; chromium-based (e.g., Cr(III)-based or Cr(VI)-based) catalysts, such as those marketed under the trade name HYCAT.™ Those available from Dimension Technology Chemical Systems, Inc., ElDorado Hills, CA; and combinations of two or more of them. In some embodiments, the catalyst is or includes a chromium-based (e.g., Cr(III)-based or Cr(VI)-based) catalyst, such as HYCAT. ™ OA. In some embodiments, it may be desirable to use a catalyst that does not contain transition metals. In some embodiments, the catalyst is or includes an imidazole derivative, such as 1,2-dimethylimidazole.

[0063] The catalyst can be included in any suitable and effective amount. The amount of catalyst can vary based on the catalyst selected. For example, the catalyst can be included in the intumescent coating composition at a concentration of 1 wt% or higher, 2 wt% or higher, 3 wt% or higher, or 4 wt% or higher of the epoxy-acid system. The catalyst can be included in the intumescent coating composition at a concentration of 5 wt% or lower, 4 wt% or lower, 3 wt% or lower, or 2 wt% or lower of the epoxy-acid system. The catalyst can be included in the intumescent coating composition at a concentration of 1 wt% to 5 wt%, 1.5 wt% to 4.5 wt%, 2 wt% to 4 wt%, or 2.5 wt% to 3.5 wt% of the epoxy-acid system.

[0064] Intumescent coating compositions may also contain a variety of optional additives, such as rheology modifiers, fillers, foam stabilizers, pigments, flame spread control agents, etc.

[0065] Examples of suitable rheology modifiers that may be used include modified derivatives of castor oil, clay and modified urea solutions, and combinations of two or more of them.

[0066] The filler can be reinforcing filler and other suitable fillers. Examples of suitable fillers that can be used include glass fiber, ceramic fiber, graphite fiber, glass flakes, mica, wollastonite, metal oxides, clay, talc, silica, diatomaceous earth, and combinations thereof. The total concentration of the filler can be preset to up to 50% by weight of the intumescent coating composition.

[0067] Preparation method

[0068] A method for preparing an intumescent coating composition includes: mixing an epoxy component and a monofunctional carboxylic acid to form a reaction product through a ring-opening reaction of the epoxy component; and preparing the coating composition by mixing the intumescent component with the reaction product and a monomer mixture.

[0069] Intumescent coating compositions can be prepared by one of two main methods: (1) preparing a monomer mixture and mixing and dissolving the epoxy component and monofunctional carboxylic acid in the monomer mixture, wherein the epoxy component and monofunctional carboxylic acid react within the monomer mixture; or (2) reacting the epoxy component and monofunctional carboxylic acid outside the monomer mixture, melting the reaction product and mixing the molten reaction product into the monomer mixture. In method (1), the monomer mixture can be heated to a temperature of about 80°C to 92°C. In method (2), the reaction product can be heated to a temperature that melts the resin, for example, about 150°C to 160°C. The molten reaction product can be gradually metered into the monomer mixture to control the temperature rise of the monomers. The reaction between the epoxy component and the monofunctional carboxylic acid can be achieved by adding the epoxy ring-opening catalyst described above. Additional components, including the intumescent component and any optional additional polymers and additives, can be added to the composition before or after the addition of the reaction product.

[0070] How to use

[0071] Before application, the intumescent coating composition can be mixed with an initiator and an accelerator to produce an activated coating composition. The initiator can be a peroxide. Suitable peroxides and concentrations are discussed above. The accelerator can be an amine accelerator. Suitable amine accelerators and concentrations are discussed above.

[0072] Intumescent coating compositions can be provided as two-part compositions. The two parts can be mixed together before application (e.g., just before application). Intumescent coating compositions can be applied using a spray applicator that mixes the two parts together just before the composition is sprayed onto the substrate.

[0073] Intumescent coating compositions can be applied to any surface or substrate requiring fire protection. Examples of substrates to which intumescent coating compositions can be applied include metals and metal alloys, such as steel, iron, aluminum, etc.; wood, plastics, ceramics, and concrete. In particular, intumescent coatings can be used to protect steel structures. Intumescent coating compositions can be applied by any suitable method, such as spraying, brushing, or rolling. In many construction applications, intumescent coating compositions are applied by spraying. Intumescent coating compositions can be mixed before or during application. Intumescent coating compositions can be applied using a single-spray applicator or a dual-spray applicator. In some embodiments, the intumescent coating composition is mixed before application and then applied by spraying using a single-spray applicator.

[0074] Intumescent coating compositions can be applied to a thickness sufficient to completely cover the substrate. For example, intumescent coating compositions can be applied to a thickness of at least 400 μm, at least 500 μm, at least 700 μm, at least 900 μm, at least 1000 μm, at least 1200 μm, at least 1400 μm, at least 1700 μm, or at least 1900 μm. Intumescent coating compositions can be applied to a thickness of up to 2000 μm, up to 1800 μm, up to 1500 μm, up to 1300 μm, up to 1100 μm, up to 900 μm, up to 700 μm, up to 600 μm, or up to 500 μm. The intumescent coating composition can be applied in thicknesses of 400 μm to 2000 μm, 500 μm to 1800 μm, 600 μm to 1700 μm, 700 μm to 1600 μm, 800 μm to 1500 μm, 900 μm to 14000 μm, 1000 μm to 13000 μm, or 1100 μm to 12000 μm.

[0075] Intumescent coating compositions can dry relatively quickly. That is, after application, the intumescent coating composition can solidify within 60 minutes or less at a temperature of 25°C or lower, 20°C or lower, 15°C or lower, or 7°C to 13°C. During curing, only a small amount (if any) of volatiles are lost from the intumescent coating composition. For example, less than 10% by weight, less than 8% by weight, less than 5% by weight, or less than 2% by weight of volatile components are lost during curing. Due to the low loss of volatiles, the final thickness of the intumescent coating is substantially similar to the thickness of the coating composition applied as described above. For example, the final thickness of the intumescent coating can be 90% or more, 95% or more, or 98% or more of the thickness of the coating composition applied.

[0076] Intumescent coating compositions can be cured via free radical polymerization. The reaction products of the epoxy component and the monofunctional carboxylic acid migrate to the surface of the coating, forming a passivation layer beneath which monomers (and any other polymerizable components present) react via free radical polymerization. The passivation layer allows free radical polymerization to proceed without oxygen inhibition.

[0077] Intumescent coating compositions can form a thin, hard coating. The hardness of the coating can be evaluated by measuring its Shore hardness, for example using the ASTM 2240 method. Shore hardness indicates the force required to indent the test material and can be used to evaluate the hardness of materials such as plastics, rubber, and elastomers. Shore hardness values ​​range from 0 to 100. A cured intumescent coating measured 24 hours after application can have a Shore D hardness of 40 or greater, 45 or greater, or 50 or greater. A cured intumescent coating measured 24 hours after application can have a Shore D hardness of 90 or less, 80 or less, or 70 or less. A cured intumescent coating measured 24 hours after application can have a Shore D hardness of 40 to 90, or 45 to 70.

[0078] Implementation Plan

[0079] The following is a list of exemplary implementations based on this disclosure.

[0080] Implementation Scheme 1 is an intumescent coating composition comprising a resin system, the resin system comprising:

[0081] The reaction products of the following substances:

[0082] Epoxy components; and

[0083] Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons;

[0084] A mixture of monomers comprising at least one olefinically unsaturated monomer; and

[0085] Expanding components,

[0086] The composition described herein can be cured by free radical polymerization.

[0087] Embodiment 2 is an intumescent coating composition according to Embodiment 1, wherein the epoxy component and the monofunctional carboxylic acid are soluble in the monomer mixture.

[0088] Embodiment 3 is an intumescent coating composition according to any one of Embodiments 1 or 2, wherein the reaction product is dissolved in the monomer mixture.

[0089] Embodiment 4 is an intumescent coating composition according to any one of Embodiments 1 to 3, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

[0090] Embodiment 5 is an intumescent coating composition according to any one of Embodiments 1 to 4, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C, and optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher, 25°C or higher, or 30°C or higher.

[0091] Embodiment 6 is an intumescent coating composition according to any one of Embodiments 1 to 5, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000, 800 to 4600, 1000 to 4000, 1500 to 3000, or 1800 to 2500.

[0092] Implementation Scheme 7 is an intumescent coating composition according to any one of Implementation Schemes 1 to 6, wherein the monofunctional carboxylic acid includes butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)9COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), octadecadienoic acid (linoleic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

[0093] Embodiment 8 is an intumescent coating composition according to any one of Embodiments 1 to 7, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl ether having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. The multifunctional epoxy resin containing glycidylamino groups, the multifunctional epoxy resin containing glycidylamino groups derived from diaminodiphenylmethane, the multifunctional epoxy resin containing glycidylamino groups derived from p-aminophenol, the multifunctional epoxy resin containing glycidyloxy groups derived from p-aminophenol, the multifunctional epoxy resin containing glycidyloxy groups derived from bisphenol A, the multifunctional epoxy resin containing glycidyloxy groups derived from bisphenol F, the multifunctional epoxy resin containing glycidyloxy groups derived from phenolic varnish, the multifunctional epoxy resin containing two or more glycidyloxy groups derived from resorcinol, or a combination of two or more of these.

[0094] Embodiment 9 is an intumescent coating composition according to any one of Embodiments 1 to 8, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of them.

[0095] Embodiment 10 is an intumescent coating composition according to any one of Embodiments 1 to 9, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

[0096] Embodiment 11 is an intumescent coating composition according to any one of Embodiments 1 to 10, further comprising an epoxy ring-opening catalyst.

[0097] Embodiment 12 is an intumescent coating composition according to Embodiment 11, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide, 1-methylimidazolium, 1,2-dimethylphosphonium bromide, etc. Imidazole, 2-methylimidazole, 2-ethylimidazole, 1-ethylimidazole, 1,3-disubstituted imidazolium salt, 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halides of Al, B, Be, Ti, Zr, Zn, Sn or Fe(III), zinc acetylacetone, zinc octoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane, chromium-based catalysts, or combinations of two or more of these.

[0098] Embodiment 13 is an intumescent coating composition according to Embodiment 11 or 12, wherein the catalyst comprises 1,2-dimethylimidazole.

[0099] Embodiment 14 is an intumescent coating composition according to any one of Embodiments 1 to 13, wherein the olefinically unsaturated monomer includes (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0100] Embodiment 15 is an intumescent coating composition according to any one of Embodiments 1 to 14, wherein the intumescent coating composition is a two-part composition, wherein the first part comprises the reaction product, the monomer mixture and the intumescent component, and wherein the second part comprises a peroxide initiator.

[0101] Embodiment 16 is an intumescent coating composition according to any one of Embodiments 1 to 15, wherein the second part further comprises an amine accelerator.

[0102] Embodiment 17 is an intumescent coating composition according to any one of Embodiments 1 to 16, wherein the resin system further comprises a polymer.

[0103] Embodiment 18 is an intumescent coating composition according to Embodiment 17, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0104] Embodiment 19 is an intumescent coating composition according to Embodiment 17 or 18, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl methacrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

[0105] Embodiment 20 is an intumescent coating composition according to any one of Embodiments 17 to 19, wherein the polymer comprises a solid thermoplastic resin.

[0106] Embodiment 21 is an intumescent coating composition according to any one of Embodiments 17 to 20, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and ethylene tert-carbonate.

[0107] Embodiment 22 is an intumescent coating composition according to any one of Embodiments 17 to 21, wherein the composition does not contain any solvent other than the monomer mixture.

[0108] Embodiment 23 is an intumescent coating composition according to any one of Embodiments 1 to 22, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

[0109] Embodiment 24 is an intumescent coating composition according to any one of Embodiments 1 to 23, wherein the reaction product accounts for 2% to 60% by weight of the intumescent coating composition.

[0110] Embodiment 25 is an intumescent coating composition according to any one of Embodiments 1 to 24, wherein the intumescent component comprises an acid source, a carbon source, and a gas source that provides intumescent gas upon thermal decomposition.

[0111] Implementation Scheme 26 is a method for preparing an intumescent coating composition, the method comprising:

[0112] An epoxy component is mixed with a monofunctional carboxylic acid with a chain length of 6 to 30 carbons to form a reaction product through a ring-opening reaction of the epoxy component; and

[0113] The coating composition is prepared by mixing the expanding component with the reaction product and a monomer mixture containing at least one olefinically unsaturated monomer.

[0114] Implementation scheme 27 is the method according to implementation scheme 26, wherein the epoxy component and the monofunctional carboxylic acid are mixed with and dissolved in the monomer mixture prior to the formation of the reaction product.

[0115] Embodiment 28 is a method according to any one of Embodiments 26 to 27, wherein the reaction product is formed prior to mixing the reaction product with the monomer mixture.

[0116] Implementation Scheme 29 is a method according to any one of Implementation Schemes 26 to 28, wherein the monofunctional carboxylic acids include butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)2COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), octadecadienoic acid (linoleic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

[0117] Embodiment 30 is a method according to any one of Embodiments 26 to 29, comprising mixing an epoxy ring-opening catalyst with the epoxy component and the monofunctional carboxylic acid.

[0118] Embodiment 31 is the method according to Embodiment 30, wherein the catalyst comprises 1,2-dimethylimidazole.

[0119] Embodiment 32 is a method according to any one of embodiments 26 to 31, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

[0120] Embodiment 33 is an intumescent coating composition according to any one of Embodiments 26 to 32, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C, and optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher, 25°C or higher, or 30°C or higher.

[0121] Embodiment 34 is an intumescent coating composition according to any one of Embodiments 26 to 33, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000, 800 to 4600, 1000 to 4000, 1500 to 3000, or 1800 to 2500.

[0122] Embodiment 35 is an intumescent coating composition according to any one of Embodiments 26 to 34, wherein the olefinically unsaturated monomer includes (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecanyl methacrylate, or a combination of two or more thereof.

[0123] Embodiment 36 is an intumescent coating composition according to any one of Embodiments 26 to 35, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing glycidylamino groups, multifunctional epoxy resins having glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins having glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins having glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins having two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

[0124] Embodiment 37 is an intumescent coating composition according to any one of Embodiments 26 to 36, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

[0125] Embodiment 38 is an intumescent coating composition according to any one of Embodiments 26 to 37, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

[0126] Embodiment 39 is a method according to any one of embodiments 26 to 38, further comprising mixing the expanded component with a polymer.

[0127] Embodiment 40 is the method according to Embodiment 39, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0128] Implementation scheme 41 is the method according to implementation scheme 39 or 40, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl methacrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

[0129] Embodiment 42 is a method according to any one of embodiments 39 to 41, wherein the polymer comprises a solid thermoplastic resin.

[0130] Embodiment 43 is a method according to any one of Embodiments 39 to 42, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and vinyl tert-carbonate.

[0131] Embodiment 44 is a method according to any one of Embodiments 26 to 43, wherein the composition does not contain any solvent other than the monomer mixture.

[0132] Embodiment 45 is the method according to any one of Embodiments 26 to 44, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

[0133] Embodiment 46 is the method according to any one of Embodiments 26 to 45, wherein the reaction product accounts for 2% to 60% by weight, 5% to 50% by weight, 10% to 50% by weight, 12% to 50% by weight, 15% to 50% by weight, 20% to 50% by weight, 25% to 50% by weight, 10% to 40% by weight, 12% to 40% by weight, 15% to 40% by weight, 20% to 40% by weight, 10% to 35% by weight, 12% to 35% by weight, 15% to 35% by weight, or 20% to 35% by weight of the intumescent coating composition.

[0134] Implementation scheme 47 is a method according to any one of implementation schemes 26 to 46, wherein the expansion component comprises an acid source, a carbon source and a gas source that provides expansion gas during thermal decomposition.

[0135] Embodiment 48 is the method according to any one of embodiments 26 to 47, further comprising mixing the composition with a peroxide initiator.

[0136] Embodiment 49 is the method according to any one of Embodiments 26 to 48, further comprising mixing the composition with an amine promoter.

[0137] Embodiment 50 is the method according to any one of Embodiments 26 to 49, wherein the composition is capable of being cured by free radical polymerization.

[0138] Implementation scheme 51 is a method for coating a substrate with an intumescent coating, the method comprising:

[0139] A liquid-expanding coating composition is mixed with an initiator and an amine accelerator to produce an activated coating composition, said liquid-expanding coating composition comprising:

[0140] The reaction products of the following substances:

[0141] Epoxy components; and

[0142] Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons;

[0143] A mixture of monomers comprising at least one olefinically unsaturated monomer; and

[0144] Expanding components;

[0145] The activated coating composition is applied to the substrate; and

[0146] The activated coating composition is cured into a solid state under environmental conditions to form the intumescent coating.

[0147] Embodiment 52 is the method according to Embodiment 51, wherein the liquid expansion coating composition is cured by free radical polymerization.

[0148] Embodiment 53 is the method according to Embodiment 51 or 52, wherein the epoxy component and the monofunctional carboxylic acid are dissolved in the monomer mixture.

[0149] Embodiment 54 is the method according to any one of embodiments 51 to 53, wherein the reaction product is dissolved in the monomer mixture.

[0150] Embodiment 55 is a method according to any one of embodiments 51 to 54, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

[0151] Embodiment 56 is an intumescent coating composition according to any one of Embodiments 51 to 55, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C, and optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher, 25°C or higher, or 30°C or higher.

[0152] Embodiment 57 is an intumescent coating composition according to any one of Embodiments 51 to 56, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000, 800 to 4600, 1000 to 4000, 1500 to 3000, or 1800 to 2500.

[0153] Embodiment 58 is an intumescent coating composition according to any one of Embodiments 51 to 57, wherein the olefinically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0154] Embodiment 59 is an intumescent coating composition according to any one of Embodiments 51 to 58, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing glycidylamino groups, multifunctional epoxy resins having glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins having glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins having glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins having two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

[0155] Embodiment 60 is an intumescent coating composition according to any one of Embodiments 51 to 59, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

[0156] Embodiment 61 is an intumescent coating composition according to any one of Embodiments 51 to 60, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

[0157] Embodiment 62 is a method according to any one of embodiments 51 to 61, wherein the liquid-expanding coating composition further comprises a polymer.

[0158] Embodiment 63 is the method according to Embodiment 62, wherein the polymer comprises at least one of a homopolymer, copolymer or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0159] Embodiment 64 is the method according to Embodiment 62 or 63, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl methacrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

[0160] Embodiment 65 is a method according to any one of embodiments 62 to 64, wherein the polymer comprises a solid thermoplastic resin.

[0161] Embodiment 66 is a method according to any one of Embodiments 62 to 65, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and ethylene tert-carbonate.

[0162] Embodiment 67 is a method according to any one of Embodiments 51 to 66, wherein the initiator comprises an organic peroxide, optionally wherein the organic peroxide comprises a diacyl peroxide, a ketone peroxide, a peroxide ester, a dialkyl peroxide, a hydroperoxide, a peroxide ketal, or a combination of two or more thereof.

[0163] Embodiment 68 is a method according to any one of embodiments 51 to 67, wherein the composition does not contain any solvent other than the monomer mixture.

[0164] Embodiment 69 is a method according to any one of embodiments 51 to 68, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

[0165] Embodiment 70 is the method according to any one of Embodiments 51 to 69, wherein the reaction product accounts for 2% to 60% by weight, 5% to 50% by weight, 10% to 50% by weight, 12% to 50% by weight, 15% to 50% by weight, 20% to 50% by weight, 25% to 50% by weight, 10% to 40% by weight, 12% to 40% by weight, 15% to 40% by weight, 20% to 40% by weight, 10% to 35% by weight, 12% to 35% by weight, 15% to 35% by weight, or 20% to 35% by weight of the intumescent coating composition.

[0166] Embodiment 71 is a method according to any one of embodiments 51 to 70, wherein the expansion component comprises an acid source, a carbon source, and a gas source that provides expansion gas during thermal decomposition.

[0167] Embodiment 72 is the method according to any one of Embodiments 51 to 71, wherein the activated coating composition is cured at a temperature of 25°C or lower, optionally at a temperature of 20°C or lower, optionally at a temperature of 15°C or lower, optionally at a temperature of 7°C to 13°C for 60 minutes or less.

[0168] Implementation scheme 73 is the method according to any one of implementation schemes 51 to 72, wherein less than 5% by weight of volatile components are lost through evaporation during the curing period.

[0169] Embodiment 74 is the method according to any one of embodiments 51 to 73, wherein the intumescent coating has a Shore D hardness of 45 to 90 or 45 to 70 measured 24 hours after application.

[0170] Implementation Scheme 75 is a method according to any one of Implementation Schemes 51 to 74, wherein the monofunctional carboxylic acids include butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)9COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), octadecadienoic acid (linoleic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

[0171] Implementation scheme 76 is a kit for applying an intumescent coating to a substrate, the kit comprising:

[0172] The first part comprises a resin system, the resin system comprising:

[0173] The reaction products of the following substances:

[0174] Epoxy components; and

[0175] Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons;

[0176] A mixture of monomers comprising at least one olefinically unsaturated monomer; and

[0177] Expanding components; and

[0178] The second part contains a peroxide initiator and an amine promoter.

[0179] Embodiment 77 is the kit according to Embodiment 76, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C.

[0180] Embodiment 78 is a kit according to Embodiment 76 or 77, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000, 800 to 4600, 1000 to 4000, 1500 to 3000, or 1800 to 2500.

[0181] Embodiment 79 is a kit according to any one of Embodiments 76 to 78, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher, 25°C or higher, or 30°C or higher.

[0182] Embodiment 80 is a kit according to any one of Embodiments 76 to 79, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl ether having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing glyceryl amino groups, multifunctional epoxy resins containing glycidyl amino groups derived from diaminodiphenylmethane, multifunctional epoxy resins containing glycidyl amino groups derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins containing glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins containing two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

[0183] Embodiment 81 is a kit according to any one of Embodiments 76 to 80, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

[0184] Embodiment 82 is a kit according to any one of Embodiments 76 to 81, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

[0185] Implementation scheme 83 is a kit according to any one of implementation schemes 76 to 82, wherein the monofunctional carboxylic acid includes butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)9COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), octadecadienoic acid (linoleic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

[0186] Implementation scheme 84 is a kit according to any one of implementation schemes 76 to 83, and further includes an epoxy ring-opening catalyst.

[0187] Embodiment 85 is the kit according to Embodiment 84, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide, 1-methylimidazole, 1,2-dimethylimidazole, 2-Methylimidazole, 2-ethylimidazole, 1-ethylimidazole, 1,3-disubstituted imidazolium salt, 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halides of Al, B, Be, Ti, Zr, Zn, Sn or Fe(III), zinc acetylacetone, zinc octoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane, chromium-based catalysts, or combinations of two or more of these.

[0188] Embodiment 86 is the kit according to Embodiment 85, wherein the catalyst comprises 1,2-dimethylimidazole.

[0189] Implementation scheme 87 is a kit according to any one of implementation schemes 76 to 86, wherein the olefinic unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0190] Embodiment 88 is a kit according to any one of Embodiments 76 to 87, wherein the resin system further comprises a polymer.

[0191] Embodiment 89 is a kit according to Embodiment 88, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0192] Embodiment 90 is a kit according to Embodiment 88 or 89, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl methacrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

[0193] Embodiment 91 is a kit according to any one of embodiments 88 to 90, wherein the polymer comprises a solid thermoplastic resin.

[0194] Embodiment 92 is a kit according to any one of Embodiments 88 to 91, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and vinyl tert-carbonate.

[0195] Embodiment 93 is a kit according to any one of embodiments 76 to 92, wherein the composition does not contain any solvent other than the monomer mixture.

[0196] Embodiment 94 is a kit according to any one of embodiments 76 to 93, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

[0197] Embodiment 95 is a kit according to any one of embodiments 76 to 94, wherein the reaction product accounts for 2% to 60% by weight, 5% to 50% by weight, 10% to 50% by weight, 12% to 50% by weight, 15% to 50% by weight, 20% to 50% by weight, 25% to 50% by weight, 10% to 40% by weight, 12% to 40% by weight, 15% to 40% by weight, 20% to 40% by weight, 10% to 35% by weight, 12% to 35% by weight, 15% to 35% by weight, or 20% to 35% by weight of the intumescent coating composition.

[0198] Implementation scheme 96 is a kit according to any one of implementation schemes 76 to 95, wherein the expansion component comprises an acid source, a carbon source and a gas source that provides expansion gas upon thermal decomposition.

[0199] Example

[0200] Various compositions with and without epoxy components and carboxylic acid reaction products were prepared.

[0201]

[0202] method

[0203] Preparation of the reaction product (adduct) of epoxy component and carboxylic acid

[0204] Add epoxy resin, long-chain carboxylic acid, butylated hydroxytoluene (BHT) as a free radical inhibitor, and monomers to a 1000 mL round-bottom reaction flask. Heat the mixture with stirring until a clear solution forms. Add 1,2-dimethylimidazole (heterocyclic), carbene, or chromium (VI) catalyst to the solution and allow the reaction to proceed. Unless otherwise specified, the reaction is carried out at 87 °C (86 °C for chromium (VI) catalyst).

[0205] Coating preparation

[0206] Unless otherwise specified, use the following amounts. Add 1% by weight of the amine promoter p-toluidine ethoxylate (BISOMER) to a 20 g sample of adduct and monomer. ® PTE; N,N-bis-(2-hydroxyethyl)-p-toluidine, an aromatic tertiary amine used as an amine activator of organic peroxides, and 0.4% by weight benzoyl peroxide (LUPEROX) ® AFR40: 40% benzoyl peroxide in dibutyl phthalate solution (1% by weight for compositions containing chromium (VI) catalyst). Mix the mixture until it has a uniform appearance, pour it into a metal pan and allow it to harden.

[0207] Hardness test

[0208] The relative hardness of the coating is measured by the ability of a circular or rounded wood chip to indent the polymer. The relative hardness test is configured to provide a relative measurement based on the indentation of the test object. During the relative hardness test, a circular wood chip is manually pressed onto the surface of the test object, leaving an indentation. The indentation of the test object indicates the relative hardness through visual estimation. Relative indentations are rated from 1 (still a liquid) to 10 (very hard solid).

[0209] Viscosity test

[0210] The tackiness of a coating can be measured by measuring the amount of sand that can adhere to the surface of the coating.

[0211] Apply the coating to a metal disc and allow it to cure for 24 hours. After curing / hardening, weigh the disc with the coating. Add enough sand to completely cover the coating surface and place a 100-gram weight on the sand for one minute at room temperature (approximately 20°C). Remove the weight and pour out the loose sand by inverting the disc and gently tapping it. Weigh the disc and its contents (including the coating) again. The weight change represents the amount of sand adhering to the coating and is a measure of the tackiness of the cured coating.

[0212] Example 1, Comparative Coatings

[0213] Comparative coating samples without adducts were prepared. This was achieved by using 10 grams of DEGALAN... ® 1720 and 10 grams of DEGALAN ® 1710 is mixed together with 1.6 grams of LUPEROX. ® A resin mixture was prepared by mixing AFR40 (40% benzoyl peroxide in dibutyl phthalate solution). DEGALAN 1710 and 1720 are acrylic monomer mixtures containing methyl methacrylate (“MMA”) and 2-ethylhexyl acrylate (“2EHA”). The mixture was poured into an aluminum pan and allowed to cure in air at room temperature for 24 hours. The sample contained 75:25 wt% MMA:2EHA.

[0214] Example 2

[0215] A coating composition comprising a mixture of MMA, 2EHA and an adduct was prepared.

[0216] The adduct was prepared by reacting EPON 1004F with a long-chain carboxylic acid (palmitic acid) via a catalytic reaction using 1,2-dimethylimidazole. EPON 1004F is a diepoxide with a molecular weight of approximately 1750. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 1 below. To prepare the coating composition as described above, 0.22 g of an amine accelerator and 1.61 g of benzoyl peroxide were added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

[0217]

[0218] The properties of the coating composition of Example 2 were evaluated and compared with those of the comparative sample of Example 1. The results are shown in Table 2.

[0219]

[0220] It has been observed that this composition can be used to prepare hard, essentially non-sticky coatings.

[0221] Example 3

[0222] A coating composition comprising a mixture of MMA, 2-octyl acrylate and an adduct was prepared.

[0223] The adduct was prepared by reacting EPON 1004F with a long-chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCAT OA. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 3 below. The coating composition was prepared as described above. An amine accelerator was added to the MMA / EHA adduct, and then 2.3 g of benzoyl peroxide was added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

[0224]

[0225] The final solids content of the coating composition is 30% by weight. The acid value of the coating composition is 37.5, and the total conversion is 97.6% (comparison between measured solids and calculated solids).

[0226] Example 4

[0227] Coating compositions similar to those in Example 3 were prepared using different amounts of catalyst.

[0228] The adduct was prepared by reacting EPON 1004F with a long-chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCAT OA. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 4 below. The coating composition was prepared as described above. An amine accelerator was added to the MMA / EHA adduct, and then 2.3 g of benzoyl peroxide was added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

[0229]

[0230] The final solids content of the coating composition is 27% by weight. The acid value of the coating composition is 41.3, and the total conversion is 88.3% (comparison between measured solids and calculated solids).

[0231] The properties of the coating compositions of Examples 3 and 4 were evaluated and compared with each other and with the comparative sample of Example 1. The results are shown in Table 5.

[0232]

[0233] It has been observed that coatings can be prepared using 2-octyl acrylate.

[0234] Example 5

[0235] A coating composition comprising a mixture of MMA, 2EHA and an adduct was prepared.

[0236] The adduct was prepared by catalytic reaction of EPON 1004F with a long-chain carboxylic acid (palmitic acid) using 1,3-dimethyl-1H-imidazolium-3-onthium-2-carboxylate as a catalyst. The catalyst had a molecular weight of 140.14. The reaction was carried out at 80°C for 5 hours. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 6 below. The coating composition was prepared as described above, with 0.22 g of amine accelerator and 1.61 g of benzoyl peroxide added to the mixture. The coating composition was applied to a surface and cured in air at room temperature. Lithium chloride in Table 6 was used as a catalyst accelerator.

[0237]

[0238] The final solids content of the coating composition was 52.25% by weight. The acid value of the coating composition was 49.4, and the total conversion was 106.79% (comparison between measured solids and calculated solids).

[0239] The properties of the coating composition were evaluated. The results are shown in Table 7.

[0240]

[0241] Example 6

[0242] A coating composition comprising a mixture of MMA, 2EHA and an adduct was prepared.

[0243] The adduct was prepared by catalytic reaction of EPON 1004F with a long-chain carboxylic acid (palmitic acid) using 1,3-dimethyl-1H-imidazolium-3-onthium-2-carboxylate as a catalyst. The reaction was carried out at 80°C for 5 hours. The molecular weight of the catalyst was 140.14 g / mol. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 8 below. The coating composition was prepared as described above, with 0.22 g of amine accelerator and 1.61 g of benzoyl peroxide added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

[0244]

[0245] The final solids content of the coating composition was 52.43% by weight. The acid value of the coating composition was 0.54, and the total conversion was 106.51% (comparison between measured solids and calculated solids).

[0246] The properties of the coating composition were evaluated. The results are shown in Table 9.

[0247]

[0248] Example 7

[0249] A coating composition comprising a mixture of MMA, 2EHA and an adduct was prepared.

[0250] The adduct was prepared by catalytic reaction of EPON 1004F with a long-chain carboxylic acid (palmitic acid) using 3-benzyl-1,2-dimethyl-1H-imidazolium-3-onium chloride as a catalyst. The reaction was carried out at 80°C for 5 hours. The molecular weight of the catalyst was 222.72 g / mol. The resulting adduct was mixed with a mixture of acrylic monomers. The amounts of the components are shown in Table 10 below. The coating composition was prepared as described above, with 0.22 g of amine accelerator and 1.61 g of benzoyl peroxide added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

[0251]

[0252] The final solids content of the coating composition was 54.45% by weight (as shown in Sample A in Table 11). The acid value of the coating composition was 1.25, and the total conversion was 109.9% (comparison between measured solids and calculated solids).

[0253] Another coating composition (as shown in Sample B in Table 11) was prepared using the same chemical composition but only half the amount of solids (27.2% by weight).

[0254] The properties of two coating compositions with different solid contents were evaluated. The results are shown in Table 11.

[0255]

[0256] Example 8

[0257] Various coating compositions were prepared to test different catalysts. The compositions were similar in all other respects. The results are shown in Table 12. The catalysts in samples 1-5 resulted in 100% ring-opening; the catalyst in sample 6 resulted in 99% ring-opening. The degree of ring-opening was evaluated using 1H-NMR. The hardness and viscosity of the samples were also tested. The results are shown in Table 13.

[0258]

[0259]

[0260] Example 9

[0261] Two resin compositions were prepared according to embodiments of this disclosure. The resin compositions were mixed with an intumescent component and other components to prepare intumescent coating compositions, which were then subjected to fire resistance tests. The samples were compared with standard coatings of the prior art (comparative samples).

[0262] The adduct was prepared from EPON 1004 (molecular weight 1750 g / mol) as the epoxy component and lauric acid (molecular weight 200.3 g / mol; sample 12A) or palmitic acid (molecular weight 256.4 g / mol; sample 12B) as the carboxylic acid. 1,2-Dimethylimidazole (DMI) was used as a catalyst, and BHT was used as a free radical inhibitor. The adduct was reacted at 150 °C. The preparation of the adduct did not involve solvents. After the preparation of the adduct, it was mixed with the monomer. The composition of the resin mixture is shown in Table 14.

[0263]

[0264] The resin mixtures of samples 12A and 12B (from the adduct and monomer mixtures in Table 14) were mixed with the same expanding and additive components as in the comparative samples. The resin used in the comparative samples was DEGALAN. Samples 12A and 12B, as well as the comparative samples, each contained approximately 35% by weight of resin. The expanding and additive materials contained approximately 50% by weight of the expanding component (a mixture of ammonium polyphosphate, melamine, and pentaerythritol); approximately 15% by weight of filler; approximately 1%-2% by weight of additives; and approximately 1% by weight of peroxide.

[0265] The hardness and tack of samples 12A and 12B were tested. The coating was applied to a hot-rolled steel sheet with dimensions of 300mm × 200mm × 5mm and subjected to a heating profile according to BS EN1363-1:2020 fire resistance test. The coating thickness was measured before and after heating. The results are shown in Table 15.

[0266]

[0267] Example 10

[0268] A coating composition comprising a mixture of MMA, 2EHA, and an adduct was prepared. The adduct was prepared by reacting EPON 1004F with a long-chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCATOA. The amounts of the components are shown in Table 16 below.

[0269]

[0270] The coating composition was prepared as described above, with variations in the amount of adduct mixed with the acrylic monomer mixture, and the addition of an amine accelerator and peroxide, as shown in Table 17. The acid value of the coating composition was 3.46. The coating composition was applied to the surface and cured in air at room temperature. The hardness of the coating (grades 1–10) was evaluated after 30, 60, and 120 minutes. Tackiness (amount of adhering sand (g)) was evaluated at 24 hours. The results are shown in Table 17.

[0271]

[0272] It has been observed that hard, substantially non-sticky coatings can be prepared from compositions containing about 20% by weight or more adducts. With increasing adduct content, the samples harden more quickly and produce harder coatings.

[0273] Example 11

[0274] Coatings with different amounts of the adduct were prepared to test the properties of the coatings. Samples were prepared as in Example 10. The amounts of the components are shown in Table 18 below. Compared to Example 10, the adduct was prepared with a higher amount of catalyst.

[0275]

[0276] The amounts of adducts mixed with the acrylic monomer mixture (containing 1.15 wt% amine and 3.05 wt% peroxide by weight of the final mixture) varied as shown in Table 19. The acid value of the coating composition was 1.91. The coating composition was applied to the surface and cured in air at room temperature. The hardness of the coating (grades 1–10) was evaluated after 30, 60, and 120 minutes. Tackiness (amount of adhering sand (g)) was evaluated at 24 hours. The results are shown in Table 19.

[0277]

[0278] It was observed that, at all tested adduct contents, the composition could produce a substantially non-sticky coating. With increasing adduct content, the samples hardened more quickly and produced a harder coating.

[0279] Example 12

[0280] Coatings with varying amounts of the adduct, EPON 1007F, and palmitic acid were prepared to test their properties. EPON 1007F is a diepoxide with a molecular weight of approximately 1700-2300. Samples were prepared as in Example 10. The amounts of the components are shown in Table 20 below.

[0281]

[0282] The amounts of adducts mixed with the acrylic monomer mixture varied as shown in Table 21. The coating composition was applied to the surface and cured in air at room temperature. The hardness of the coating (grades 1–10) was evaluated after 30, 60, 90, and 120 minutes. The results are shown in Table 21.

[0283]

[0284] Example 13

[0285] Example 10 was repeated, except that cyclohexyl methacrylate was used as the monomer. As described in Example 10, the adduct was prepared using EPON 1004F, palmitic acid, and HYCAT OA.

[0286] The coating composition was prepared as described above, with variations in the amount of adduct mixed with the acrylic monomer mixture, and the addition of an amine accelerator and peroxide, as shown in Table 22. The acid value of the coating composition was 0.72. The coating composition was applied to the surface and cured in air at room temperature for 15 minutes. The hardness of the coating (grades 1-10) was evaluated after 1 hour. Tackiness (amount of adhering sand (g)) was evaluated after 48 hours. The results are shown in Table 22.

[0287]

[0288] It has been observed that hard, substantially non-sticky coatings can be prepared from compositions containing about 20% by weight or more adducts. With increasing adduct content, the samples harden more quickly and produce harder coatings.

[0289] Example 14

[0290] A coating composition comprising a mixture of MMA, 2EHA, and an adduct was prepared. The adduct was prepared by reacting EPON 1004F, trimethylolpropane triacrylate, and butyl acrylate with a long-chain carboxylic acid (stearic acid) via a catalytic reaction using HYCATOA. The amounts of the components are shown in Table 23 below.

[0291]

[0292] The adduct was mixed with 377.3 g MMA, 94.3 g 2EHA, 0.50 wt% benzoyl peroxide, and 0.2 wt% amine. The composition had an acid value of 0.82, a solids content of 39.38%, and a conversion rate of 97.60%. The sample solidified within 45 minutes.

[0293] The samples were analyzed by thermogravimetric analysis (TGA). Heating was performed using a heating profile from 25°C to 850°C at a rate of 20°C / min, with an air flow of approximately 200 mL / min. The samples were compared with two commercially available products. TGA illustrations are shown below. Figure 1 The sample was found to be soft, but without any stickiness.

[0294] Example 15

[0295] Coating compositions with different adduct compositions were prepared and analyzed using TGA. Samples were prepared as described in Example 12, using MMA / 2EHA as the monomer. The amounts of epoxide, carboxylic acid, HYCAT OA, and BHT in the adducts are shown in Table 24 below.

[0296]

[0297] The sample was cured in air at room temperature to form a soft but non-sticky product. The sample was analyzed by TGA as described in Example 14 and compared with commercially available products. The TGA illustration is shown in... Figures 2A-2D In the study, it was found that the thermal stability of the obtained product exceeded that of commercially available products.

[0298] All references and publications cited herein are expressly incorporated in their entirety by reference unless they may directly contradict this disclosure. While specific embodiments have been illustrated and described herein, those skilled in the art will understand that various alternatives and / or equivalent embodiments may be substituted for the specific embodiments shown and described without departing from the scope of this disclosure. It should be understood that this disclosure is not intended to be unduly limited to the illustrative embodiments and examples set forth herein, and such embodiments and embodiments are presented by way of example only, and the scope of this disclosure is intended to be limited only by the claims set forth herein.

Claims

1. An intumescent coating composition comprising a resin system, the resin system comprising: The reaction products of the following substances: Epoxy components; and Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons; A mixture of monomers comprising at least one olefinically unsaturated monomer; and Expanding components, The composition described herein can be cured by free radical polymerization.

2. The intumescent coating composition according to claim 1, wherein the epoxy component and the monofunctional carboxylic acid are soluble in the monomer mixture.

3. The intumescent coating composition according to claim 1 or 2, wherein the reaction product is dissolved in the monomer mixture.

4. The intumescent coating composition according to any one of claims 1 to 3, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

5. The intumescent coating composition according to any one of claims 1 to 4, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C.

6. The intumescent coating composition according to any one of claims 1 to 5, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000.

7. The intumescent coating composition according to any one of claims 1 to 6, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher.

8. The intumescent coating composition according to any one of claims 1 to 7, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl urea group having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing oleylamine, multifunctional epoxy resins containing glycidylamine derived from diaminodiphenylmethane, multifunctional epoxy resins containing glycidylamine derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins containing glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins containing glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins containing two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

9. The intumescent coating composition according to any one of claims 1 to 8, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

10. The intumescent coating composition according to any one of claims 1 to 9, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

11. The intumescent coating composition according to any one of claims 1 to 10, further comprising an epoxy ring-opening catalyst.

12. The intumescent coating composition according to claim 11, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide, 1-methylimidazole, 1,2-dimethylimidazole 2-Methylimidazole, 2-ethylimidazole, 1-ethylimidazole, 1,3-disubstituted imidazolium salt, 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halides of Al, B, Be, Ti, Zr, Zn, Sn or Fe(III), zinc acetylacetone, zinc octoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane, chromium-based catalysts, or combinations of two or more of these.

13. The intumescent coating composition according to claim 12, wherein the catalyst comprises 1,2-dimethylimidazole.

14. The intumescent coating composition according to any one of claims 1 to 13, wherein the monofunctional carboxylic acid comprises butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and lauric acid (CH3(CH2)9COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

15. The intumescent coating composition according to any one of claims 1 to 14, wherein the olefinically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecanyl methacrylate, or a combination of two or more thereof.

16. The intumescent coating composition according to any one of claims 1 to 15, wherein the intumescent coating composition is a two-part composition, wherein the first part comprises the reaction product, the monomer mixture and the intumescent component, and wherein the second part comprises a peroxide initiator.

17. The intumescent coating composition of claim 16, wherein the second portion further comprises an amine accelerator.

18. The intumescent coating composition according to any one of claims 1 to 17, wherein the resin system further comprises a polymer.

19. The intumescent coating composition of claim 18, wherein the polymer comprises at least one homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

20. The intumescent coating composition according to claim 18 or 19, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

21. The intumescent coating composition according to any one of claims 1 to 20, wherein the polymer comprises a solid thermoplastic resin.

22. The intumescent coating composition according to any one of claims 1 to 21, wherein the polymer comprises a reaction product of one or more dienes with at least any one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and vinyl tert-carbonate.

23. The intumescent coating composition according to any one of claims 1 to 22, wherein the composition is free of solvents other than the monomer mixture.

24. The intumescent coating composition according to any one of claims 1 to 23, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

25. The intumescent coating composition according to any one of claims 1 to 24, wherein the reaction product accounts for 2% to 60% by weight of the intumescent coating composition.

26. The intumescent coating composition according to any one of claims 1 to 25, wherein the intumescent component comprises an acid source, a carbon source, and a gas source that provides intumescent gas upon thermal decomposition.

27. A method for preparing an intumescent coating composition, the method comprising: The epoxy component is mixed with a monofunctional carboxylic acid with a chain length of 6 to 30 carbons to form a reaction product through the ring-opening reaction of the epoxy component. as well as The coating composition is prepared by mixing the expanding component with the reaction product and a monomer mixture containing at least one olefinically unsaturated monomer.

28. The method of claim 27, wherein, prior to the formation of the reaction product, the epoxy component and the monofunctional carboxylic acid are mixed with and dissolved in the monomer mixture.

29. The method of claim 27 or 28, wherein the reaction product is formed prior to mixing the reaction product with the monomer mixture.

30. The method according to any one of claims 27 to 29, wherein the composition is capable of being cured by free radical polymerization.

31. The method according to any one of claims 27 to 30, comprising mixing an epoxy ring-opening catalyst with the epoxy component and the monofunctional carboxylic acid.

32. The method according to claim 31, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide, 1-methylimidazolium, 1,2-dimethylimidazolium, 2- Methylimidazole, 2-ethylimidazole, 1-ethylimidazole, 1,3-disubstituted imidazolium salt, 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halides of Al, B, Be, Ti, Zr, Zn, Sn or Fe(III), zinc acetylacetone, zinc octoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane, chromium-based catalysts, or combinations of two or more of these.

33. The method of claim 31, wherein the catalyst comprises 1,2-dimethylimidazole.

34. The method according to any one of claims 27 to 33, wherein the monofunctional carboxylic acid comprises butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and lauric acid (CH3(CH2)2COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

35. The method according to any one of claims 27 to 34, wherein the olefinically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecanyl methacrylate, or a combination of two or more thereof.

36. The method according to any one of claims 27 to 35, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

37. The method according to any one of claims 27 to 36, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C.

38. The method according to any one of claims 27 to 37, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000.

39. The method according to any one of claims 27 to 38, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher.

40. The method according to any one of claims 27 to 39, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl ether having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing amino groups, multifunctional epoxy resins having glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins having glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins having glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins having two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

41. The method according to any one of claims 27 to 40, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

42. The method according to any one of claims 27 to 41, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

43. The method according to any one of claims 27 to 42, further comprising mixing the expanded component with the polymer.

44. The method of claim 43, wherein the polymer comprises at least one homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

45. The method according to claim 43 or 44, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

46. ​​The method according to any one of claims 43 to 45, wherein the polymer comprises a solid thermoplastic resin.

47. The method according to any one of claims 43 to 46, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and ethylene tert-carbonate.

48. The method according to any one of claims 27 to 47, wherein the composition does not contain any solvent other than the monomer mixture.

49. The method according to any one of claims 27 to 48, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

50. The method according to any one of claims 27 to 49, wherein the reaction product accounts for 2% to 60% by weight of the intumescent coating composition.

51. The method according to any one of claims 27 to 50, wherein the expanding component comprises an acid source, a carbon source, and a gas source that provides expanding gas during thermal decomposition.

52. The method according to any one of claims 27 to 51, further comprising mixing the composition with a peroxide initiator.

53. The method according to any one of claims 27 to 52, further comprising mixing the composition with an amine accelerator.

54. A method for coating a substrate with an intumescent coating, the method comprising: A liquid-expanding coating composition is mixed with an initiator and an amine accelerator to produce an activated coating composition, said liquid-expanding coating composition comprising: The reaction products of the following substances: Epoxy components; and Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons; A mixture of monomers comprising at least one olefinically unsaturated monomer; and Expanding components; The activated coating composition is applied to the substrate; as well as The activated coating composition is cured into a solid state under environmental conditions to form the intumescent coating.

55. The method of claim 54, wherein the liquid-expanding coating composition is cured by free radical polymerization.

56. The method according to claim 54 or 55, wherein the epoxy component and the monofunctional carboxylic acid are dissolved in the monomer mixture.

57. The method according to any one of claims 54 to 56, wherein the reaction product is dissolved in the monomer mixture.

58. The method according to any one of claims 54 to 57, wherein the monofunctional carboxylic acid comprises butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)2COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

59. The method according to any one of claims 54 to 58, wherein the olefinically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecanyl methacrylate, or a combination of two or more thereof.

60. The method according to any one of claims 54 to 59, wherein the epoxy component comprises an epoxy resin containing two or more epoxy groups.

61. The method according to any one of claims 54 to 60, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C.

62. The method according to any one of claims 54 to 61, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000.

63. The method according to any one of claims 54 to 62, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20°C or higher.

64. The method according to any one of claims 54 to 63, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracite diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl ether having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing amino groups, multifunctional epoxy resins having glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins having glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins having glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins having two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

65. The method according to any one of claims 54 to 64, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

66. The method according to any one of claims 54 to 65, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

67. The method according to any one of claims 54 to 66, wherein the liquid-expanding coating composition further comprises a polymer.

68. The method of claim 67, wherein the polymer comprises at least one homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

69. The method according to claim 67 or 68, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

70. The method according to any one of claims 67 to 69, wherein the polymer comprises a solid thermoplastic resin.

71. The method according to any one of claims 67 to 70, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and ethylene tert-carbonate.

72. The method according to any one of claims 54 to 71, wherein the initiator comprises an organic peroxide.

73. The method according to any one of claims 54 to 72, wherein the composition does not contain any solvent other than the monomer mixture.

74. The method according to any one of claims 54 to 73, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

75. The method according to any one of claims 54 to 74, wherein the reaction product accounts for 2% to 60% by weight of the intumescent coating composition.

76. The method according to any one of claims 54 to 75, wherein the expanding component comprises an acid source, a carbon source, and a gas source that provides expanding gas during thermal decomposition.

77. The method according to any one of claims 54 to 76, wherein the activated coating composition is cured at a temperature of 25°C or lower for 60 minutes or less.

78. The method according to any one of claims 54 to 77, wherein less than 5% by weight of volatile components are lost from the coating composition by evaporation during the curing process.

79. The method according to any one of claims 54 to 78, wherein the intumescent coating has a Shore D hardness of 45 to 90 measured 24 hours after application.

80. A kit for applying an intumescent coating to a substrate, the kit comprising: The first part comprises a resin system, the resin system comprising: The reaction products of the following substances: Epoxy components; and Monofunctional carboxylic acids with chain lengths of 6 to 30 carbons; A mixture of monomers comprising at least one olefinically unsaturated monomer; and Expanding components; and The second part contains a peroxide initiator and an amine promoter.

81. The kit of claim 80, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20°C.

82. The kit according to claim 80 or 81, wherein the epoxy component comprises an epoxy resin with a molecular weight in the range of 500 to 5000.

83. The kit according to any one of claims 80 to 82, wherein the epoxy component comprises an epoxy resin with a glass transition temperature of 20°C or higher.

84. The kit according to any one of claims 80 to 83, wherein the epoxy component comprises an epoxy resin, said epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxynaphthalene diglycidyl ether, dihydroxyanthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycidyl urea, a multifunctional epoxy resin having a glycidyl amino group derived from m-phenylenediamine, or a glycidyl ether having a glycidyl amino group derived from 1,3-bis(aminomethyl)cyclohexane. Multifunctional epoxy resins containing amino groups, multifunctional epoxy resins having glycidylamino groups derived from diaminodiphenylmethane, multifunctional epoxy resins having glycidylamino groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from p-aminophenol, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol A, multifunctional epoxy resins having glycidyloxy groups derived from bisphenol F, multifunctional epoxy resins having glycidyloxy groups derived from phenolic varnish, multifunctional epoxy resins having two or more glycidyloxy groups derived from resorcinol, or combinations of two or more of these.

85. The kit according to any one of claims 80 to 84, wherein the epoxy component comprises an epoxy resin, the epoxy resin comprising a multifunctional epoxy resin having a glycidyl group derived from bisphenol A, a multifunctional epoxy resin having a glycidyl group derived from bisphenol F, a multifunctional epoxy resin having a glycidyl group derived from phenolic varnish, a multifunctional epoxy resin having two or more glycidyl groups derived from resorcinol, or a combination of two or more of the above.

86. The kit according to any one of claims 80 to 85, wherein the epoxy component comprises a multifunctional epoxy resin having a glycidyl group derived from bisphenol A.

87. The kit according to any one of claims 80 to 86 further comprises an epoxy ring-opening catalyst.

88. The kit of claim 87, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethylamine, n,n-dimethylbenzylamine, dodecyldimethylbenzylamine, tetramethylguanidine, triethylenediamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethylphosphonium bromide, 1-methylimidazolium, 1,2-dimethylimidazolium, 2- Methylimidazole, 2-ethylimidazole, 1-ethylimidazole, 1,3-disubstituted imidazolium salt, 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halides of Al, B, Be, Ti, Zr, Zn, Sn or Fe(III), zinc acetylacetone, zinc octoate, zinc acetate, boron trifluoride, trimethoxycycloboroxane, chromium-based catalysts, or combinations of two or more of these.

89. The kit according to claim 87 or 88, wherein the monofunctional carboxylic acid comprises butyric acid (CH3(CH2)2COOH), valeric acid (CH3(CH2)3COOH), caproic acid (CH3(CH2)4COOH), heptaic acid (CH3(CH2)5COOH), caprylic acid (CH3(CH2)6COOH), nonanoic acid (CH3(CH2)7COOH), capric acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), and dodecanoic acid (CH3(CH2)2COOH). 10 COOH), tridecanoic acid (CH3(CH2)) 11 COOH), myristic acid (CH3(CH2)) 12 COOH), pentadecanoic acid (CH3(CH2)) 13 COOH), hexadecanoic acid (palmitic acid) (CH3(CH2) 14 COOH), heptadecanoic acid (pearlacic acid) (CH3(CH2) 15 COOH), octadecanoic acid (stearic acid) (CH3(CH2) 16 COOH), nonadecanoic acid (CH3(CH2)) 17 COOH), eicosanoic acid (arachidic acid) (CH3(CH2) 18 COOH), or a combination of two or more thereof, optionally wherein said monofunctional carboxylic acid includes hexadecanoic acid (palmitic acid) (CH3(CH2)). 14 COOH).

90. The kit according to any one of claims 87 to 89, wherein the catalyst comprises 1,2-dimethylimidazole.

91. The kit according to any one of claims 80 to 90, wherein the olefinically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecanyl methacrylate, or a combination of two or more thereof.

92. The kit according to any one of claims 80 to 91, wherein the resin system further comprises a polymer.

93. The kit of claim 92, wherein the polymer comprises at least one homopolymer, copolymer, or terpolymer of methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

94. The kit according to claim 92 or 93, wherein the polymer comprises a reaction product of at least one of the following substances: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate and 2-octyl acrylate.

95. The kit according to any one of claims 92 to 94, wherein the polymer comprises a solid thermoplastic resin.

96. The kit according to any one of claims 92 to 95, wherein the polymer comprises a reaction product of one or more dienes with at least one of the following substances: styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, and vinyl tert-carbonate.

97. The kit according to any one of claims 80 to 96, wherein the composition is free of solvents other than the monomer mixture.

98. The kit according to any one of claims 80 to 97, wherein the monomer mixture accounts for 30% to 90% by weight of the resin system.

99. The kit according to any one of claims 80 to 98, wherein the reaction product accounts for 2% to 60% by weight of the intumescent coating composition.

100. The kit according to any one of claims 80 to 99, wherein the expansion component comprises an acid source, a carbon source, and a gas source that provides expansion gas upon thermal decomposition.

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