Heat insulating and flame retardant non-intemescent coating and method for producing same

Abstract

The coating includes a polymer resin that does not contain an intumescent material, a pulverized nanoporous material, and a solid portion of a flame-retardant solution. The pulverized nanoporous material and the solid portion of the flame-retardant solution are incorporated into the polymer resin to form a thermal insulating and flame-retardant coating having a uniform consistency. Methods of forming the coating are also disclosed.

Description

[Technical Field]

[0001] The present disclosure relates to non-intumescent coatings, and more particularly to thermally insulating and flame-retardant non-intumescent coatings, and methods for making such non-intumescent coatings. [Background technology]

[0002] Conventional intumescent paints may provide some passive thermal protection, but generally only when exposed to heat (and expansion) in the range of 200-250 degrees Celsius. At ambient temperatures, neither intumescent nor non-intumescent paints act significantly as thermal barriers. That is, neither intumescent nor non-intumescent paints generally offer protection against heat loss through conduction or radiation, and therefore do not provide significant insulating value.

[0003] Furthermore, such intumescent paints may need to be applied in multiple layers to achieve the thickness required for the intumescent element to properly expand and function as a flame retardant when the coated object is exposed to flame or high temperatures. Obtaining a smooth surface finish with intumescent paints is difficult in achieving the required coating thickness. Without the intumescent element, the base resin of the paint is generally flammable. Summary of the Invention [Problem to be solved by the invention]

[0004] Thus, there is a need for a thermal barrier coating that, at ambient temperatures, reduces heat loss by radiation or conduction and reduces or prevents heat transfer, for example, through thermal bridges. In the event of a fire, such a coating should also be flame-retardant (and / or heat-resistant) to protect the underlying structure (the object being coated) from the fire / heat. Such a coating should also desirably provide thermal and fire / heat-resistant properties at a relatively thin coating thickness, whether obtained through a single coating or multiple coatings, and should provide a relatively smooth coating surface. [Means for solving the problem]

[0005] The above and other needs are met by aspects of the present disclosure, which in one aspect provides a method of forming a coating comprising adding a pulverized nanoporous material and solids of a fire retardant solution to a polymer resin that does not contain an intumescent material to form a thermal insulating and fire retardant coating having a uniform consistency.

[0006] Another aspect of the present disclosure provides a method of forming a coating comprising combining a nanoporous material with a fire retardant solution such that the nanoporous material absorbs the fire retardant solution; evaporating liquid from the nanoporous material that has absorbed the fire retardant solution such that a concentrate or solid of the fire retardant solution remains within the nanoporous material; and adding the nanoporous material with the concentrate or solid of the fire retardant solution therein to a polymer resin that does not contain an intumescent material to form a thermal insulating and fire retardant coating of uniform consistency.

[0007] Yet another aspect of the present disclosure provides a coating comprising a polymer resin that does not contain an intumescent material, a pulverized nanoporous material, and solids of a fire-retardant solution, wherein the pulverized nanoporous material and solids of the fire-retardant solution are incorporated into the polymer resin to form a thermally insulating and fire-retardant coating of uniform consistency.

[0008] The present disclosure therefore includes, but is not limited to, the following embodiments:

[0009] Embodiment 1: A method of forming a coating comprising adding solids of a pulverized nanoporous material and a flame retardant solution to a polymer resin that does not contain an intumescent material to form a thermally insulating, flame retardant coating having a uniform consistency.

[0010] Embodiment 2: The method of any preceding embodiment or any combination of the preceding embodiments, wherein adding the pulverized nanoporous material and the solids of the fire retardant solution to the polymer resin comprises adding the pulverized silica-based nanoporous material and the solids of the fire retardant solution to the polymer resin.

[0011] Embodiment 3: The method of any preceding embodiment or any combination of the preceding embodiments, wherein adding the pulverized nanoporous material and the solids of the fire-retardant solution to the polymer resin comprises adding the pulverized silica aerogel nanoporous material and the solids of the fire-retardant solution to the polymer resin.

[0012] Embodiment 4: The method of the preceding embodiment or any combination of the preceding embodiments, wherein adding the pulverized nanoporous material and the solids of the fire retardant solution to the polymer resin comprises adding the pulverized nanoporous material and the solids of the fire retardant solution to a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

[0013] Embodiment 5: The method of any preceding embodiment or combination of the preceding embodiments, comprising evaporating a liquid from the flame retardant solution to form a solid of the flame retardant solution.

[0014] Embodiment 6: The method of any preceding embodiment or combination of the preceding embodiments, wherein evaporating the liquid from the flame retardant solution comprises spray drying the flame retardant solution.

[0015] Embodiment 7: The method of the preceding embodiment or any combination of the preceding embodiments, wherein evaporating liquid from the flame retardant solution comprises evaporating liquid from a flame retardant solution comprising boron compounds, phosphorus compounds, chlorine compounds, lithium compounds, fluorine compounds, antimony compounds, borate compounds, boric acid, inorganic hydrates, bromine compounds, aluminum compounds, magnesium hydroxide, phosphonium salts, zirconium salts, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or combinations thereof.

[0016] Embodiment 8: The method of any preceding embodiment or any combination of the preceding embodiments, comprising treating the pulverized nanoporous material to render the pulverized nanoporous material hydrophilic prior to adding the pulverized nanoporous material and the solids of the flame retardant solution to the polymer resin.

[0017] Embodiment 9: The method of any preceding embodiment or any combination of the preceding embodiments, comprising adding a surfactant, a thickener, a pigment, a fiber, or a combination thereof to the polymer resin.

[0018] Embodiment 10: A method of forming a coating comprising combining a nanoporous material with a fire retardant solution such that the nanoporous material absorbs the fire retardant solution; evaporating liquid from the nanoporous material that has absorbed the fire retardant solution such that a concentrate or solid of the fire retardant solution remains within the nanoporous material; and adding the nanoporous material having the concentrate or solid of the fire retardant solution therein to a polymer resin that does not contain an intumescent material to form a thermal insulating and fire retardant coating of uniform consistency.

[0019] Embodiment 11: The method of any preceding embodiment or any combination of the preceding embodiments, wherein combining the nanoporous material and the flame retardant solution comprises combining a silica-based nanoporous material and the flame retardant solution.

[0020] Embodiment 12: The method of any preceding embodiment or any combination of the preceding embodiments, wherein combining the nanoporous material and the flame-retardant solution comprises combining a silica aerogel nanoporous material and the flame-retardant solution.

[0021] Embodiment 13: The method of the preceding embodiment or any combination of the preceding embodiments, wherein combining the nanoporous material with the flame retardant solution comprises combining the nanoporous material with a flame retardant solution comprising a boron compound, a phosphorus compound, a chlorine compound, a lithium compound, a fluorine compound, an antimony compound, a borate compound, boric acid, an inorganic hydrate, a bromine compound, an aluminum compound, magnesium hydroxide, a phosphonium salt, a zirconium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or a combination thereof.

[0022] Embodiment 14: The method of any preceding embodiment or any combination of the preceding embodiments, wherein evaporating liquid from the nanoporous material having the flame-retardant solution absorbed therein comprises spray-drying the flame-retardant solution.

[0023] Embodiment 15: The method of any preceding embodiment or any combination of the preceding embodiments, comprising treating the nanoporous material to render the nanoporous material hydrophilic prior to combining the nanoporous material with the flame retardant solution.

[0024] Embodiment 16: The method of any preceding embodiment or any combination of the preceding embodiments, wherein adding the nanoporous material having the flame retardant solution concentrate or solid therein to the polymer resin comprises adding the nanoporous material having the flame retardant solution concentrate or solid therein to a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or combinations thereof.

[0025] Embodiment 17: The method of any preceding embodiment or any combination of the preceding embodiments, comprising adding a surfactant, a thickener, a pigment, a fiber, or a combination thereof to the polymer resin.

[0026] Embodiment 18: A coating comprising a polymer resin that does not contain an intumescent material, a pulverized nanoporous material, and solids of a flame-retardant solution, wherein the pulverized nanoporous material and solids of the flame-retardant solution are incorporated into the polymer resin to form a thermal insulating and flame-retardant coating having a uniform consistency.

[0027] Embodiment 19: The coating of any preceding embodiment or combination of the preceding embodiments, wherein the milled nanoporous material comprises a milled silica-based nanoporous material.

[0028] Embodiment 20: The coating of any preceding embodiment or combination of the preceding embodiments, wherein the milled nanoporous material comprises a milled silica aerogel nanoporous material.

[0029] Embodiment 21: A coating of any preceding embodiment or combination of the preceding embodiments, wherein the solids of the flame retardant solution are derived from evaporation of liquid from the pulverized nanoporous material having the flame retardant solution contained within and absorbed therein.

[0030] Embodiment 22: The coating of any preceding embodiment or combination of the preceding embodiments, further comprising a concentrate of the fire-retardant solution contained within the pulverized nanoporous material derived from partial evaporation of liquid from the pulverized nanoporous material having the fire-retardant solution absorbed therein.

[0031] Embodiment 23: The coating of any combination of the preceding embodiments, or any combination of the preceding embodiments, wherein the polymer resin comprises a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

[0032] Embodiment 24: The coating of any preceding embodiment or combination of the preceding embodiments, wherein the solids of the flame retardant solution comprise crystalline solids resulting from evaporation of liquid from the flame retardant solution.

[0033] Embodiment 25: The coating of any combination of the preceding embodiments, or any combination of the preceding embodiments, wherein the flame retardant solution comprises a boron compound, a phosphorus compound, a chlorine compound, a lithium compound, a fluorine compound, an antimony compound, a borate compound, boric acid, an inorganic hydrate, a bromine compound, an aluminum compound, magnesium hydroxide, a phosphonium salt, a zirconium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or a combination thereof.

[0034] Embodiment 26: The coating of any preceding embodiment or combination of the preceding embodiments, wherein the milled nanoporous material comprises a hydrophilic milled nanoporous material.

[0035] Embodiment 27: The coating of any preceding embodiment or any combination of the preceding embodiments, wherein the flame retardant solution comprises one of an aqueous flame retardant solution, a non-toxic liquid flame retardant solution, and a neutral pH liquid flame retardant solution.

[0036] Embodiment 28: The coating of any preceding embodiment or combination of the preceding embodiments, comprising a surfactant, a thickener, a pigment, a fiber, or a combination thereof incorporated into the polymer resin.

[0037] These and other features, aspects, and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined or recited in the description of a particular embodiment herein. The present disclosure, in all of its aspects and embodiments, is intended to be read holistically, such that any separable features or elements of the disclosure are deemed combinable as intended, i.e., unless the context of the disclosure clearly dictates otherwise.

[0038] It will be understood that this Summary is provided merely for the purpose of summarizing some exemplary aspects to provide a basic understanding of the present disclosure. Accordingly, it will be understood that the exemplary aspects described above are merely examples and should not be construed to narrow the scope or spirit of the present disclosure in any way. It will be understood that the scope of the present disclosure encompasses many potential aspects in addition to those summarized herein, some of which are further described below. Furthermore, other aspects disclosed herein and advantages of such aspects will become apparent from the following detailed description, taken in conjunction with the accompanying figures, which illustrate, by way of example, the principles of the described aspects.

[0039] Having thus described the disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief explanation of the drawings]

[0040] [Figure 1] 1 illustrates a schematic diagram of a method for forming a coating according to one aspect of the present disclosure. [Figure 2] 10A and 10B illustrate a schematic representation of a method of forming a coating according to another aspect of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0041] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, aspects of the disclosure are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0042] FIG. 1 illustrates a schematic diagram of a method for forming a coating, generally designated by element 100. According to certain embodiments of the present disclosure, such a method includes adding a pulverized nanoporous material 120 and a solid portion of a flame-retardant solution 140 to a polymeric resin 160 that does not contain an intumescent material to form a thermal insulating and flame-retardant coating 180 having a uniform consistency. In some examples, the pulverized nanoporous material 120 includes a pulverized silica-based or silicon dioxide-based nanoporous material. In other specific examples, the pulverized nanoporous material 120 includes a pulverized silica (silicon dioxide) aerogel nanoporous material. Examples of such nanoporous materials include any commercially available amorphous silica (silicon dioxide) material commonly referred to as aerogel. In certain embodiments of the present disclosure, the polymeric resin 160 includes a vinyl chloride resin. However, those skilled in the art will understand that the polymeric resin 160 can include many different compounds, particularly compounds that can be applied to a surface as a coating, such as a paint. In certain embodiments, the selection of the polymer resin can depend on several factors, including the heat resistance (e.g., temperature level and / or duration) required for the resulting coating. More specifically, examples of suitable alternative polymer resins implemented in connection with the present disclosure include vinyl acetate ethylene copolymer resins, styrene-acrylic resins, acrylic resins, polyurethane resins, silicone resins, epoxy resins, butadiene resins, vinyl acrylate resins, silicate resins, vinyl acetate-butyl acrylate copolymer resins, carboxylated polymer resins, polyvinylidene fluoride polymer resins, or combinations thereof. In certain embodiments of the present disclosure, the selected polymer resin has a glass transition temperature in the range of about -30°C to about +25°C.

[0043] Non-limiting examples of suitable nanoporous materials that may be implemented as nanoporous material 120 in connection with the present disclosure may include Enersens Kwark® aerogel, Svenska Quartzene® Z1 aerogel, Cabot Enova® aerogel, and JIOS AeroVa® aerogel. In one example, nanoporous material 120 may include, for example, NANOLIT® carbon aerogel and / or UNINANO TS-Powder® aerogel, which generally exhibit high surface area and exhibit heat resistance. In particular, NANOLIT® has a surface area of ​​about 700 to about 1500 m 2 / g surface area and a density of about 0.5 g / cc, while TS-Powder® has a surface area of ​​about 600 to about 1000 m 2 / g surface area and a density of about 0.06 to about 0.38 g / cc. Such exemplary aerogels generally exhibit low thermal conductivity λ and do not absorb liquid water (are hydrophobic), but are permeable to water vapor. Generally, such exemplary aerogels do not contain fungicides, algicides, pesticides, binders, or flame retardants, and do not react with other materials. However, one skilled in the art will understand that nanoporous materials can include many different compounds, organic or inorganic (e.g., precipitated silica), available under many different trade names.

[0044] The nanoporous material may be optionally refined to obtain the pulverized nanoporous material 120 disclosed herein in connection with the coating 180 and its manufacturing method. For example, the nanoporous material may be chopped, ground, crushed, or subjected to other suitable processing to reduce and pulverize the larger elements of the nanoporous material into smaller elements having a desired level of refinement, as reflected, for example, in the average particle size range. In coating 180 according to embodiments of the present disclosure, the nanoporous material, once pulverized, may desirably have an average element size ranging from about 0.5 mm to about 1.5 mm. In some embodiments of the present disclosure, very fine particles of nanoporous material, typically with an average element size of less than about 0.1 mm, may be added (e.g., in addition to the pulverized nanoporous material) to fit or fill the interstices between the larger particles of the pulverized nanoporous material. The nanoporous material may be pulverized by mechanical processing, such as through a hammer mill or other suitable processing equipment.

[0045] In some embodiments, the flame-retardant solution solids 140 can be obtained or produced by evaporating the liquid from the flame-retardant solution, with the flame-retardant solution solids 140 remaining after the deliquification process. According to certain embodiments of the present disclosure, the flame-retardant solution includes a boron compound, a phosphorus compound, a chlorine compound, a lithium compound, a fluorine compound, an antimony compound, a borate compound, boric acid, an inorganic hydrate, a bromine compound, an aluminum compound, magnesium hydroxide, a phosphonium salt, a zirconium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or a combination thereof. Furthermore, the flame-retardant solution can be implemented as one of an aqueous flame-retardant solution, a non-toxic liquid flame-retardant solution, and a neutral pH liquid flame-retardant solution. The evaporation process may include, for example, heating the flame-retardant solution to evaporate the liquid from the flame-retardant solution until only the solids 140 (e.g., precipitate in the form of crystalline solids) of the flame-retardant solution remain. Such a process may be similar to, for example, obtaining salt crystals by heating a salt solution such that the water in the solution evaporates and the salt crystals remain as a precipitate. In another example, the evaporation process may include, for example, subjecting the flame-retardant solution to a spray-drying procedure.

[0046] Once the flame-retardant solution solids 140 are obtained, they can be refined as appropriate to achieve the appropriate level of refinement disclosed herein in connection with the coatings and methods for their manufacture. For example, the solids may be chopped, ground, crushed, or subjected to other suitable processing to reduce and pulverize larger elements of the solids into smaller elements with the desired level of refinement, as reflected, for example, in the average particle size range. In coatings according to embodiments of the present disclosure, the solids, once pulverized, may desirably have an average element size equal to or less than the average element size of the pulverized nanoporous material (e.g., about 0.5 mm to about 1.5 mm). In some embodiments of the present disclosure, it may be desirable for the flame-retardant solution solids to be very fine particles, with an average element size of less than about 0.1 mm. The solids may be pulverized / refined by mechanical processing, such as through a hammer mill or other suitable processing equipment.

[0047] The pulverized nanoporous material 120 and the flame-retardant solution solids 140 can then be combined with the polymer resin 160 to form a uniformly consistent insulating and flame-retardant coating 180. That is, the pulverized nanoporous material 120 and the flame-retardant solution solids 140 may be added to and substantially uniformly dispersed throughout the polymer resin 160 in sufficient amounts so that the coating 180 exhibits a uniform or even consistency and appears smooth when applied to a surface. If the nanoporous material (e.g., NANOLIT®) is hydrophobic, whether as manufactured or due to post-manufacturing treatment, the nanoporous material need not be made hydrophilic (but may be made hydrophilic if desired) before being combined with the flame-retardant solution solids 140 and the polymer resin 160.

[0048] The insulating properties of the nanoporous material and the flame / fire resistance imparted to the nanoporous material and polymer resin by the flame-retardant solution solids 140 thus eliminate the need for other flame-retardant substances in the coating 180, such as, for example, intumescent materials. However, in some embodiments, intumescent materials / components may be added / included in addition to (but not instead of) the flame-retardant solution solids disclosed herein. The resulting coating 180 thus generally lacks intumescent material components, particularly as certain solids of the flame-retardant solution, in certain embodiments of the present disclosure, and is therefore commonly referred to as a non-intomescent coating. Furthermore, the insulating properties of the nanoporous material impart significant as-applied insulating value (e.g., passive or ambient insulating value) to the resulting coating 180, for example, compared to intumescent-based coatings, which generally only provide significant insulating value upon activation / activation. For example, a single coating or layer of a coating according to embodiments of the present disclosure, which may have a thickness of about 2 mm to about 5 mm (typically, the coating may have a single coating thickness of about 0.5 mm to about 10 mm), when applied and cured, may exhibit an insulating "R-value" (e.g., a passive or ambient insulating value). This as-applied insulating value of a coating according to embodiments of the present disclosure is greater than that of a conventional intumescent coating of comparable thickness (e.g., 1 mm to 10 mm). Furthermore, conventional intumescent coatings, when applied to a surface, generally result in a rough or textured coating on the surface.

[0049] When exposed to a fire / flame at temperatures of about 200°C to about 250°C, which represents the activation temperature of typical intumescent materials, a conventional intumescent coating with an applied thickness of 1 mm expands to a layer approximately 40 mm thick. By expanding in response to heat / flame, conventional intumescent coatings provide a thermal barrier to the underlying coated surface. However, the resin matrix supporting the intumescent particles / materials is not necessarily flame-retardant, which can limit the flame-retardant performance of the intumescent coating in some cases. In comparison, while the nanoporous material and polymer resin implemented in the coatings of the present disclosure are not necessarily flame-retardant, the implementation and inclusion of solids in the flame-retardant solution imparts flame-retardant properties to both the nanoporous material and the polymer resin components of the coating. Thus, while both coatings according to embodiments of the present disclosure and conventional intumescent-based coatings provide thermal protection when the coating is exposed to fire / flame, the thermal protection of the underlying surface and the fire resistance of the coating are greater for coatings according to embodiments of the present disclosure compared to conventional intumescent-based coatings.

[0050] Those skilled in the art will further appreciate that other elements, such as, for example, surfactants, thickeners, pigments, fibers, or combinations thereof, may be added to the polymer resin as needed or desired for the properties and purposes these additional elements provide. In some specific embodiments of the present disclosure, the polymer resin comprises from about 30 weight percent to about 80 weight percent of the total coating composition.

[0051] In another embodiment of the present disclosure, as shown in Figure 2, instead of combining the pulverized nanoporous material 120 and the solids 140 of the fire-retardant solution with the polymer resin 160 as shown in Figure 1, the nanoporous material and the fire-retardant solution may be first combined (block 220) so that the nanoporous material absorbs the liquid fire-retardant solution. The nanoporous material may or may not be pulverized / purified prior to combination with the fire-retardant solution. Once absorbed, or combined for a time sufficient to allow absorption, the liquid is evaporated from the nanoporous material with the fire-retardant solution absorbed therein so that the concentrate and / or solids of the fire-retardant solution remain within the nanoporous material (block 240).

[0052] Those skilled in the art will appreciate that the liquid can be evaporated from the nanoporous material having the flame-retardant solution absorbed therein in a variety of suitable manners. For example, the nanoporous material having the flame-retardant solution absorbed therein may be heated to evaporate the liquid. In other examples, the nanoporous material having the flame-retardant solution absorbed therein may have the liquid evaporated therefrom by subjecting the saturated nanoporous material to a heating process, a spray-drying process, and / or any other suitable process to remove at least some of the liquid from the flame-retardant solution absorbed by the nanoporous material. That is, this may be sufficient to evaporate at least a portion or a certain amount of the liquid from the flame-retardant solution such that a precipitate of a more concentrated (less liquid) flame-retardant solution, a more concentrated flame-retardant solution, and / or solids of the flame-retardant solution remain substantially within the pores or associated with the surface of the nanoporous material. As previously disclosed, the fire retardant solution combined with and absorbed by the nanoporous material may include boron compounds, phosphorus compounds, chlorine compounds, lithium compounds, fluorine compounds, antimony compounds, borate compounds, boric acid, inorganic hydrates, bromine compounds, aluminum compounds, magnesium hydroxide, phosphonium salts, zirconium salts, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or combinations thereof.

[0053] In some embodiments, it may be necessary or desirable to first treat the nanoporous material to render it hydrophilic prior to combining the nanoporous material with the flame-retardant solution. That is, the nanoporous material (e.g., NANOLIT®) may be hydrophobic at the time of manufacture, e.g., to prevent the nanoporous material from absorbing moisture from the surrounding environment, or may be hydrophobic as a result of a post-manufacturing treatment applied by the manufacturer (e.g., rendered hydrophobic through the use of a silylating agent). Thus, prior to being implemented as disclosed herein, particularly in instances where a liquid flame-retardant solution is absorbed by the nanoporous material, the nanoporous material can first be treated to render it hydrophilic. More specifically, in some instances, an exemplary silylating agent used to render a hydrophilic nanoporous material hydrophobic is trimethylchlorosilane (TMCS), which has a boiling point of 57°C. To remove TMCS and / or any other silylating agent from the treated (hydrophobic) nanoporous material, for example, the treated nanoporous material may be placed in a forced (air) circulation oven and heated to a temperature approximately 10° C. below the boiling point of the silylating agent used to render the nanoporous material hydrophobic (e.g., heating the hydrophobic nanoporous material to a specific temperature related to the boiling point of the silylating agent without sintering the nanoporous material).

[0054] Once the hydrophilic nanoporous material having the flame-retardant solution absorbed therein has been processed to remove (e.g., evaporate or dehydrate) a sufficient amount of liquid associated with the flame-retardant solution, the nanoporous material having the flame-retardant solution concentrate and / or solids therein may be optionally comminuted / purified (block 260) to achieve the appropriate level of purification as disclosed herein in connection with the coating and its manufacturing method. For example, the nanoporous material having the flame-retardant solution concentrate and / or solids therein may be chopped, grinded, crushed, or subjected to other suitable processing to reduce and comminute / purify its larger elements into smaller elements of the desired level of purification, as reflected, for example, in the average particle size range. In coatings according to embodiments of the present disclosure, the nanoporous material having the flame-retardant solution concentrate and / or solids therein, once comminuted, may desirably have an average element size ranging from about 0.5 mm to about 1.5 mm. In some embodiments of the present disclosure, very fine particles of nanoporous material having a fire-retardant solution concentrate and / or solids therein, typically with an average element size of less than about 0.1 mm, may be added (e.g., in addition to the pulverized nanoporous material having a fire-retardant solution concentrate and / or solids therein) to fit or fill the interstices between the larger sized particles of the pulverized nanoporous material having a fire-retardant solution concentrate and / or solids therein. The nanoporous material having a fire-retardant solution concentrate and / or solids therein may be pulverized / purified by mechanical processing, such as through a hammer mill or other suitable processing equipment.

[0055] The purified pulverized nanoporous material having the fire retardant solution concentrate and / or solids therein may then be combined with a polymer resin (block 280) to form a thermal insulating and fire retardant coating 300 having a uniform consistency, as disclosed elsewhere herein. That is, the purified pulverized nanoporous material having the fire retardant solution concentrate and / or solids therein may be added to, and dispersed substantially evenly throughout, the polymer resin in a sufficient amount such that the coating exhibits a uniform or even consistency, and the coating appears smooth when applied to a surface. The insulating properties of the nanoporous material and the flame / fire resistance imparted to the nanoporous material and polymer resin (e.g., by the flame retardant solution concentrate and / or solids leaching from the nanoporous material into the polymer resin when the pulverized nanoporous material having the flame retardant solution concentrate and / or solids therein is added to or combined with the polymer resin) therefore eliminate the need for other flame retardant substances in the coating, such as, for example, intumescent materials. Thus, the resulting coating, according to certain aspects of the present disclosure, does not contain an intumescent material component and thus can be referred to as a non-intomescent coating. Furthermore, the insulating properties of the nanoporous material impart significant insulating value to the resulting coating, as compared to, for example, intumescent coatings, as disclosed elsewhere herein, while providing a relatively smooth coating compared to, for example, intumescent coatings. Additionally, and as disclosed elsewhere herein, those skilled in the art will further appreciate that other elements, such as, for example, surfactants, thickeners, pigments, fibers, or combinations thereof, may be added to the polymer resin as needed or desired for the properties and purposes these additional elements provide. In some specific embodiments of the present disclosure, the polymer resin comprises from about 30 weight percent to about 80 weight percent of the total coating composition.

[0056]

[0006] One aspect of the present disclosure therefore provides a coating comprising an intumescent-free polymeric resin, a pulverized nanoporous material, and a solid portion of a flame-retardant solution, wherein the pulverized nanoporous material and the solid portion of the flame-retardant solution are incorporated into the polymeric resin to form a thermal insulating and flame-retardant coating having a uniform consistency. The pulverized nanoporous material may comprise a pulverized silica-based nanoporous material, more specifically, a pulverized silica aerogel nanoporous material. The polymeric resin may comprise a vinyl chloride resin or other suitable resin material, such as a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

[0057] The solids of the flame retardant solution include crystalline solids resulting from evaporation of liquid from the flame retardant solution. Such flame retardant solutions may include boron compounds, phosphorus compounds, chlorine compounds, lithium compounds, fluorine compounds, antimony compounds, borate compounds, boric acid, inorganic hydrates, bromine compounds, aluminum compounds, magnesium hydroxide, phosphonium salts, zirconium salts, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or combinations thereof.

[0058] In some embodiments, the pulverized nanoporous material and the solids of the flame-retardant solution are processed separately before being combined in the polymer resin. In other embodiments, the solids of the flame-retardant solution and / or the concentrate of the flame-retardant solution are contained within the nanoporous material (either by pulverizing the nanoporous material prior to combination with the flame-retardant solution or by pulverizing during combination) and result from evaporation of liquid from the nanoporous material with the flame-retardant solution absorbed therein. Due to the absorption of the flame-retardant solution, the nanoporous material comprises a hydrophilic nanoporous material. Additionally, one or more surfactants, thickeners, pigments, fibers, or combinations thereof can be incorporated into the polymer resin during coating formation, as needed or desired. In some specific embodiments of the present disclosure, the polymer resin comprises about 30 weight percent to about 80 weight percent of the total coating composition.

[0059] Thus, aspects of the present disclosure provide a coating / paint that can provide significant thermal insulation properties through nanoporous materials in both fire-exposed and ambient temperature conditions. Furthermore, the inclusion of a fire-retardant solution and / or solids of the fire-retardant solution imparts fire-retardant properties to both the nanoporous material and the polymer resin, most of which are not fire-resistant. The heat resistance of the coating can depend on the selection of the specific polymer resin on which the coating is based. Generally, the nanoporous material, the components of the fire-retardant solution, and the polymer resin are mixed together until a smooth paste or viscous liquid is obtained as the resulting coating. The resulting thermally insulating and fire-retardant coating (without the intumescent components) can be applied by brush, spray, roller, etc. The coating / paint may be applied, for example, to masonry, plasterboard, or wood surfaces, or to the columns or surfaces of steel structures, particularly for the smooth aesthetic appearance of the coated surface.

[0060] Numerous modifications and other embodiments of the inventions described herein will occur to those skilled in the art to which these disclosed embodiments pertain having the benefit of the teachings presented in the foregoing description and the associated drawings. It is understood, therefore, that embodiments of the invention are not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the present invention. Furthermore, while the foregoing description and the associated drawings describe exemplary embodiments in connection with particular example combinations of elements and / or functions, it should be understood that various combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the present disclosure. In this regard, for example, combinations of elements and / or functions other than those explicitly described above are also contemplated within the scope of the present disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0061] While terms such as first, second, etc. may be used herein to describe various steps or calculations, it should be understood that these steps or calculations are not limited by these terms. These terms are used only to distinguish one operation or calculation from another. For example, a first calculation could be referred to as a second calculation, and similarly, a second step could be referred to as a first step, without departing from the scope of this disclosure. As used herein, the term "and / or" and the " / " symbol include any and all combinations of one or more of the associated listed items.

[0062] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Accordingly, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

Claims

1. 1. A method of forming a non-intemescent coating, comprising: adding a pulverized nanoporous material and solids of an aqueous flame retardant solution to a polymer resin lacking an intumescent material to form a thermally insulating, flame retardant, non-intomescent coating without the addition of an intumescent material; and treating the pulverized nanoporous material to render it hydrophilic prior to adding the pulverized nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin, said treating comprising heating the pulverized nanoporous material without sintering the pulverized nanoporous material. Including, method.

2. 10. The method of claim 1, wherein adding the pulverized nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin comprises adding a pulverized silica-based nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin.

3. 10. The method of claim 1, wherein adding the pulverized nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin comprises adding pulverized silica aerogel nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin.

4. 10. The method of claim 1, wherein adding the pulverized nanoporous material and the solids of the aqueous fire-retardant solution to the polymer resin comprises adding the pulverized nanoporous material and the solids of the aqueous fire-retardant solution to a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

5. The method of claim 1 , comprising evaporating a liquid from the aqueous fire retardant solution to form the solid mass of the aqueous fire retardant solution.

6. The method of claim 5 , wherein evaporating liquid from the aqueous flame retardant solution comprises spray drying the aqueous flame retardant solution.

7. 6. The method of claim 5, wherein evaporating liquid from the aqueous flame retardant solution comprises evaporating liquid from the aqueous flame retardant solution comprising boron compounds, phosphorus compounds, chlorine compounds, lithium compounds, fluorine compounds, antimony compounds, borate compounds, boric acid, inorganic hydrates, bromine compounds, aluminum compounds, magnesium hydroxide, phosphonium salts, zirconium salts, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or combinations thereof.

8. The method of claim 1 , comprising adding a surfactant, a thickener, a pigment, a fiber, or a combination thereof to the polymer resin.

9. 1. A method of forming a coating, comprising: combining the nanoporous material with an aqueous fire retardant solution such that the nanoporous material absorbs the aqueous fire retardant solution; treating the nanoporous material to render it hydrophilic prior to combining the nanoporous material with the aqueous fire-retardant solution such that the nanoporous material absorbs the aqueous fire-retardant solution; evaporating liquid from the nanoporous material having the aqueous fire-retardant solution absorbed therein such that a concentrate or solids of the aqueous fire-retardant solution remains within the nanoporous material; adding a nanoporous material having a concentrate or solids of the aqueous flame retardant solution therein to a polymer resin lacking an intumescent material to form a thermally insulating, flame retardant coating; A method of forming a coating comprising:

10. 10. The method of claim 9, wherein combining the nanoporous material with the aqueous fire-retardant solution comprises combining a silica-based nanoporous material with the aqueous fire-retardant solution.

11. 10. The method of claim 9, wherein combining the nanoporous material with the aqueous fire-retardant solution comprises combining a silica aerogel nanoporous material with the aqueous fire-retardant solution.

12. 10. The method of claim 9, wherein combining the nanoporous material with the aqueous flame retardant solution comprises combining the nanoporous material with the aqueous flame retardant solution comprising a boron compound, a phosphorus compound, a chlorine compound, a lithium compound, a fluorine compound, an antimony compound, a borate compound, boric acid, an inorganic hydrate, a bromine compound, an aluminum compound, magnesium hydroxide, a phosphonium salt, a zirconium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or a combination thereof.

13. 10. The method of claim 9, wherein evaporating liquid from the nanoporous material having the aqueous flame retardant solution absorbed therein comprises spray drying the nanoporous material having the aqueous flame retardant solution absorbed therein.

14. 10. The method of claim 9, wherein adding the nanoporous material having a concentrate or solids of the aqueous fire retardant solution therein to a polymer resin comprises adding the nanoporous material having a concentrate or solids of the aqueous fire retardant solution therein to a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

15. The method of claim 9, comprising adding a surfactant, a thickener, a pigment, a fiber, or a combination thereof to the polymer resin.

16. a polymer resin lacking an intumescent material; a hydrophilic milled nanoporous material; a solid of an aqueous fire retardant solution; A non-intemescent coating comprising: the solids of the aqueous fire-retardant solution are contained within the pulverized nanoporous material; A non-intemescent coating, wherein the pulverized nanoporous material and the solids of the aqueous fire retardant solution are incorporated into the polymer resin to form a thermally insulating, fire retardant, non-intemescent coating.

17. 17. The coating of claim 16, wherein the milled nanoporous material comprises a milled silica-based nanoporous material.

18. 17. The coating of claim 16, wherein the crushed nanoporous material comprises a crushed silica aerogel nanoporous material.

19. 17. The coating of claim 16, wherein the solids of the aqueous fire retardant solution result from evaporation of liquid from the pulverized nanoporous material having the aqueous fire retardant solution absorbed therein.

20. 20. The coating of claim 19, further comprising a concentrate of the aqueous flame retardant solution contained within the pulverized nanoporous material resulting from partial evaporation of liquid from the pulverized nanoporous material having the aqueous flame retardant solution absorbed therein.

21. 17. The coating of claim 16, wherein the polymer resin comprises a vinyl chloride resin, a vinyl acetate ethylene copolymer resin, a styrene-acrylic resin, an acrylic resin, a polyurethane resin, a silicone resin, an epoxy resin, a butadiene resin, a vinyl acrylate resin, a silicate resin, a vinyl acetate-butyl acrylate copolymer resin, a carboxylated polymer resin, a polyvinylidene fluoride polymer resin, or a combination thereof.

22. 17. The coating of claim 16, wherein the solids of the aqueous fire retardant solution comprise crystalline solids resulting from evaporation of liquid from the aqueous fire retardant solution.

23. 17. The coating of claim 16, wherein the aqueous flame retardant solution comprises a boron compound, a phosphorus compound, a chlorine compound, a lithium compound, a fluorine compound, an antimony compound, a borate compound, boric acid, an inorganic hydrate, a bromine compound, an aluminum compound, magnesium hydroxide, a phosphonium salt, a zirconium salt, ammonium phosphate, diammonium phosphate, methyl bromide, methyl iodide, bromochlorodifluoromethane, dibromotetrafluoroethane, dibromodifluoromethane, urea, or a combination thereof.

24. 17. The coating of claim 16, wherein the aqueous fire retardant solution comprises one of a non-toxic liquid fire retardant solution and a pH neutral liquid fire retardant solution.

25. 17. The coating of claim 16, comprising a surfactant, a thickener, a pigment, a fiber, or a combination thereof incorporated into the polymer resin.

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