Active and passive flame-retardant, intumescent and water-repellent coating systems for fire protection

Abstract

The present invention discloses active and passive flame-retardant, intumescent and water-repellent coating systems for fire protection, the passive system modality comprising a novel composition of a flame-retardant, intumescent and water-repellent coating with preventive passive fire protection properties and technology that are not offered by similar products available today. Said composition is water-based and is manufactured and designed to provide fire protection to the steel metal bearing structures in mixed-use buildings, walls, floors, and between floors by means of thin rigid layers of the composition which provide excellent strength and thermal protection, generating a thermal insulating barrier against the ignition source and, once combustion has started, providing robust protection when exposed to high temperatures and extreme turbulent forces of any type of fire generated either due to cellulosic fire or hydrocarbon fire. In the active system modality, the composition is in powder, aerosol or silicone form.

Description

[0001] Fireproof, intumescent and water-repellent coating systems

[0002] PASSIVE AND ACTIVE FIRE DEFENSE

[0003] Field of Invention

[0004] The focus of this invention is on the fire prevention industry. Those familiar with the art will understand that the characteristics of a passive fire-resistant coating can be easily adapted and found use in industries such as construction, warehousing, forestry, and many other related industries.

[0005] Background of the Invention.

[0006] The prior art in the field of this invention includes, for example, patent document US 4,529,467, which describes a curable intumescent composition containing an epoxy resin, a curing agent, and an additive, the latter comprising a source of phosphoric acid, zinc borate, and a blowing agent. Such a composition may have the disadvantage of being able to generate contamination and toxicity during a fire.

[0007] International patent application PCT / GB2002 / 001393 discloses a fire retardant intumescent coating composition comprising: (a) 30 to 60% by weight of a phosphorus-containing material, which decomposes to produce phosphoric acid when the coating is exposed to fire; (b) 10 to 30% by weight of a thermosetting binder; (c) 2.5 to 10% by weight of a curing agent for the thermosetting binder, and (d) 5 to 40% by weight of a thermoplastic binder binder, wherein the active groups of the thermosetting and thermoplastic binders are chosen to impart charring and blowing functions to the intumescent coating composition. Advantageously, the thermosetting binder is a hydroxylated thermosetting binder, suitably an epoxy resin. The thermoplastic binder is advantageously an oxygenated heterocyclic thermoplastic binder, suitably an aldehyde and / or ketone resin.The coating composition may contain from 1 to 10% by weight of a coloring agent, suitably titanium dioxide. The coating composition may contain from 0.1 to 10% by weight of a melt viscosity modifier, suitably hydrogenated castor oil. The fire-retardant intumescent coating composition of this application may form a carbonaceous layer that is porous, soft, and brittle, with inadequate resistance to fire turbulence.

[0008] International patent application PCT / EP2014 / 064892 discloses a thermosetting intumescent coating composition suitable for protecting substrates against hydrocarbon fires, e.g., jet fires. The coating composition can be used without a support mesh. The invention disclosed in that patent application also relates to substrates coated with the intumescent coating composition and to a method for protecting structures against fire. However, such an intumescent coating composition may not be able to protect steel, which upon heating loses structural strength within the first 10 minutes of a hydrocarbon fire.

[0009] International patent application PCT / EP2014 / 064893 discloses a liquid intumescent coating composition comprising the following components: (a) from 25.0 to 75.0% by volume of one or more thermostable organic polymer(s), one or more curing agent(s) for the thermostable organic polymer(s), (b) from 1.0 to 70.0% by volume of a phosphoric or sulfonic acid source, (c) from 6.0 to 60.0% by volume of a boric acid source, (d) from 0 to 2.0% by volume of melamine or melamine derivatives, (e) from 0 to 1.0% by volume of one or more isocyanurate derivatives, wherein the volume percentage of components (a), (b), (c), (d) and (e) is calculated on the total volume of non-volatile components in the coating composition. The thermosetting intumescent coating composition is suitable for protecting substrates against hydrocarbon fires, e.g., jet fires.The coating composition can be used without a support mesh. The invention disclosed in international patent application PCT / EP2014 / 064893 also relates to substrates coated with the intumescent coating composition and to a method of protecting structures against fire.

[0010] The thermosetting organic polymer of (a) may comprise at least one of the following functional groups: epoxy, amine, ester, vinyl, vinyl ester, amide, urethane, mercaptan, carboxylic acid, acryloyl, methacryloyl, isocyanate, alkoxysilyl, anhydride, hydroxyl, alkoxy and polythiol groups.

[0011] An example of a thermosetting organic polymer of (a) is an epoxy resin. Preferably, the thermosetting organic polymer of (a) is an epoxy resin, its curing agent being one selected from an amine-, thiol-, carboxylic acid-, anhydride-, and / or alcohol-functional curing agent.

[0012] Preferably, the thermosetting organic polymer(s) do not comprise a polysiloxane chain. The thermosetting organic polymer and the curing agent are capable of curing to form a coating on a substrate. A polysiloxane chain is defined as a structure having a Si-O backbone or support structure with organic side groups bonded to silicon atoms via a carbon or heteroatom bond, wherein at least some of the silicon atoms are bonded to one, two or three oxygen atoms.

[0013] The thermosetting organic polymer has an organic nature. By organic nature, we mean that the polymer system contains carbon. By definition, therefore, the organic polymer may not comprise purely inorganic polymeric or oligomeric silicate structures, for example, sodium or potassium silicate. Additional coatings where the binder is solely an alkali silicate are water-leachable and would not provide a heavy-duty / weather (water / corrosion)-resistant film suitable for protection against hydrocarbon fires.

[0014] The thermosetting organic polymer may, however, contain heteroatoms and may contain, for example, alkoxysilyl functional groups. Since the thermosetting organic polymer contains carbon, an additional carbonizing agent is not an essential component in the coating composition. The thermosetting organic polymer may comprise one or a mixture of more than one of the following functional groups: epoxy, amine, ester, vinyl, vinyl ester, amide, urethane, mercaptan, carboxylic acid, acryloyl, methacryloyl, isocyanate, alkoxysilyl, anhydride, hydroxyl, alkoxy and polythiol. The liquid intumescent coating composition described in this application when exposed to heat or direct fire can generate carbonaceous layers that expand 50 to 100 times their dry thickness, this carbon foam is porous, soft, brittle with inadequate resistance to withstand the turbulence of a cellulosic type fire and hydrocarbon type.

[0015] International patent application PCT / CN2017 / 088391 relates to an intumescent coating composition, a multi-component intumescent coating product, methods of applying the intumescent coating composition or the multi-component intumescent coating product to substrates coated with the intumescent coating composition or the multi-component intumescent coating product. The intumescent coating composition and the multi-component intumescent coating product of the invention may have excellent low-temperature resistance and fire-fighting properties. However, the applied layers may char over time to contain the fire, but no backing layer may remain to protect the substrate, compromising the structural stability of buildings.

[0016] Brief Description of the Invention

[0017] The present invention generally provides passive and active fire-resistant, intumescent and water-repellent coating systems, which in its passive system form comprise a new composition of a fire-resistant, intumescent and water-repellent coating with properties and technology of passive preventive fire protection not shown by similar products available until now.This composition is water-based and is manufactured and designed to protect load-bearing steel structures in mixed buildings, walls, floors, and between floors against fire by means of rigid thin layers of the composition that provide excellent resistance and thermal protection, generating a thermal insulating barrier against the ignition source and, once combustion has started, providing robust protection when exposed to high temperatures and extreme turbulent forces in any type of fire generated by either cellulosic or hydrocarbon fire.

[0018] This invention provides a fire-resistant, intumescent, and water-repellent coating system with high thermal protection values ​​not offered by current products described in the prior art. Each applied thin rigid layer of the composition of this invention surprisingly does not peel off or disintegrate due to its high adhesion properties to the substrate, and between each applied layer, it protects each element coated with it from exposure to a cellulosic fire, which is generated in front of a combustion source, where said coated elements are materials such as steel, concrete, wood, paper, plastic, cardboard, textiles, drywall, Styrofoam, among others.

[0019] According to international standards such as UL-263, cellulosic fires reach temperatures ranging from 1000 to 1200°F (538 to 649°C) where the steel does not burn; however, in a fire, the steel heats up and loses its structural strength within the first 10 minutes of a fire.

[0020] The present application discloses a fire-resistant, intumescent, and water-repellent coating system with surprisingly high values ​​of protection, cohesion, strength, and thermal protection that can be applied in at least one thin, rigid layer of the coating system composition.In addition, the composition of this coating system has a natural vitreous finish that unexpectedly does not crack, peel or disintegrate, due to its surprisingly high adhesion properties to the substrate and between each applied layer of the composition, which protect against exposure to a fire by combustible hydrocarbons such as gas, oil, gasoline, diesel, hydrosine, jet fuel, kerosene, which spread in seconds through pipes, pipelines and other materials in critical condition that break, spill and can immediately generate fire, generating puddle fires, fire jet fires in both marine and terrestrial environments, in oil and gas facilities.

[0021] Safe, immediate, and effective fire protection solutions are required. According to international standards, hydrocarbon fires reach temperatures of 2100°F (1149°C) within 5 minutes, based on test curves of at least UL-1709.

[0022] Conventional intumescent paints, when applied to steel structures for building construction, have a cured dry thickness of 4 to 8 millimeters, depending on the structure. When exposed to high temperatures, these paints expand their thermally insulating carbonaceous layer by 50 to 100 times its thickness, above 482 ° F (250 ° C), which causes the major problem of delaying the heating of the steel, for no more than 60 to 120 minutes of protection. Therefore, conventional intumescent paints maintain the temperature of the steel below 932 ° F (500 ° C), protecting the strength of the steel when a fire starts, with a carbonaceous layer that is fragile to the turbulence of fires. In addition, all layers applied according to their required thickness are carbonized at the same time, at the time of their expansion and fire protection.

[0023] The novel and surprising fireproof, intumescent and water repellent coating of the present invention provides a first rigid thin layer with a thickness of 0.2524 thousandths of an inch (0.006411 mm) that supports 1652 to 2192 ° F (900 to 1200 ° C) of temperature, in determined times of 60 minutes for each thin and rigid layer, to protect the substrate by means of its excellent adhesion properties not seen at the time of the creation of the present invention, thus guaranteeing the stability of the steel or other construction materials and the second rigid thin layer exposed to fire does not allow heat transfer, keeping it below its critical flow temperature, of less than 932 ° F (500 ° C), even with high temperatures of the nature of 2012 ° F (1100 ° C).By applying the novel and surprising coating composition of the present invention, steel and other construction materials are protected in the event of a high-temperature fire, maintaining their stability and preventing them from collapsing, within specific times of 30 to 240 minutes, by means of its rigid thin coating layers, preventing the spread of the flames to other adjacent areas where the most important thing is that the start of the fire is contained at the place where it started and that it is mitigated there by encapsulating the fire without generating toxic fumes. If it is also applied to walls and ceilings, it delays, mitigates and minimizes the effects of fire in any mixed building, protecting real estate and with the main objective of safeguarding people's lives.

[0024] The novel and surprising composition of the fireproof, intumescent and water-repellent coating for passive fire protection of the present invention comprises the following components: a) a dehydrating agent, b) a binding agent, c) a source of organic acid, d) a source of organic carbon, e) organic polymers, f) a fireproof agent, g) thermosetting elastomers, h) an organic adhesive agent, i) a resin agent, and j) a fiber agent.

[0025] The composition of a passive technology fire-resistant, intumescent, and water-repellent coating of the present invention comprises a suitable dehydrating agent that requires, but is not restricted to: a group of naturally occurring fibrous metamorphic minerals composed of double-chain silicates, complexes of iron, aluminum, sodium, and magnesium. Wherein the preferred dehydrating agent is sodium silicate fibers.

[0026] Such a dehydrating agent may comprise minerals that are part of the phyllosilicate group, a powdered absorbent and a fire-resistant mineral clay, which is notable for its high porosity, and a mineral to prevent bacterial fermentation. One of its great characteristics is that it has an excellent capacity to absorb liquids, including water, solvents or hydrocarbon oils, and acts as a containment barrier.

[0027] Such dehydrating agent comprises natural mineral acrylics hydrated in fiber or powder, sodium, iron, aluminum and magnesium complexes, which are known to be non-toxic, non-corrosive, inert, and not dangerous to health or the environment, in addition to being 100% biodegradable.

[0028] In the fireproof, intumescent and water repellent coating composition of the present invention, the amount of the dehydrating agent is representative of 8% to 19% based on the total weight of the composition, preferably 9-16% by weight, more preferably 10-17% by weight, and even more preferably 10-14% by weight.

[0029] The dehydrating agent comprises a fireproof mineral clay, which due to its enormous porosity, is an absorbent of liquids such as water when heat is generated and / or a temperature increase of between 248 and 356 °F (120 to 180 °C). Its main function in this process is the extraction of water from the binding agent, dissolving silicates with alkaline cations and anions or analogous to chains, such as sodium ortho-silicate and metasilicate, which are quite soluble in water.

[0030] In one embodiment, the passive technology fire-resistant, intumescent, and water-repellent coating composition according to the present invention comprises a binding agent, which is not restricted to the family of ortho-silicates, metasilicates, and pyro-silicates, since any ester containing a chemical group, such as tetramethyl ortho-silicate, may also be used. A preferred binding agent according to the present invention is liquid or powdered sodium silicate.

[0031] As water is removed and / or absorbed from the liquid silicate, the silicate becomes progressively more viscous, the removal of water will convert the silicate into a glass film and microscopic quartz flakes, with a 3:2 weight ratio, are better suited to act as a film binder the lower alkaline content of a 3:2 silicate provides less affinity for water.

[0032] Polymerization reactions occur if the pH falls below 10.7, silicates react with acid compounds, these crosslink to form "polymers", the anions of the solutions depend on the concentration of the solution, the temperature and several factors, when the dissolved silicates are acidified generally by decomposition between 392 to 482 ° F (200 to 250 ° C), acids are produced that react with other aggregates of the fireproof coating.

[0033] When the dehydration of the silicate solution occurs by the hydrolysis of the ester and the neutralization of the solution, it reacts in the acid to form the acetate anion, being a carboxylate and is the base of the acid formed by the deprotonation of acetic acid, which is released which changes the pH value to acid, it is a safe and environmentally friendly process.

[0034] Silicates dehydrated by esters, generate a hardening as a result of hydrolysis reactions, subsequent to the dispersion of the ester in the binder, the ester gradually hydrolyzes forming a weak acid and an alcohol, the acid reacts with the silicate to form potassium and sodium salt, and the union of hydroxyl groups (OH) in silicon resulting in gelation, the mixed union of the silicate and the type of ester used can generate, glycerol diacetate, ethylene glycol diacetate and glycerol tricetate, these are the most commercial esters used in compositions of the state of the art in conventional coatings.

[0035] In the waterborne fire-resistant and intumescent coating composition of the present invention, the amount of binding agent is representative of 46% to 61% based on the total weight of the composition, preferably 46-59% by weight, more preferably 49-60% by weight, even more preferably 48-61% by weight and even more preferably 48-56% by weight.

[0036] The passive technology fire-resistant, intumescent, and water-repellent coating composition of the present invention comprises a suitable acid source that requires but is not restricted to producing acid or acids when the coating of the present invention is exposed to fire.

[0037] The acid contains attached silicon, this family of compounds has the formula [SiO x (OH) 4-2 x]n 23; some simple silicic acids are found in divided aqueous solutions, such as metasilicic acid (H2S03), orthosilicic acid (H4S04, PKal = 9.84, PKa2 = 13.2 at 25 °C), disilicic acid (H2S02O5) and pyro-silicic acid (H6S02O7) which in the solid state condense to form polymeric silicic acids with a complex structure.

[0038] The fireproof, intumescent and water-repellent coating composition of passive technology of the present invention comprises a source of organic acid, preferably citric acid additive to silicic acid obtained by acidification of silicate salts.

[0039] The amount of the organic acid source is representative of 0.4 to 2.9% based on the total weight of the flame-retardant coating composition, preferably 0.4-2.2% by weight, more preferably 0.4-2.7% by weight, even more preferably 0.6-2.9% by weight, and even more preferably 0.5-2.5%.

[0040] Source of Organic Carbon Carbohydrates

[0041] The fireproof, intumescent, and water-repellent coating composition with passive fire protection properties and technology of the present invention comprises an organic carbon source. When the fireproof, intumescent, and water-repellent coating is exposed to fire or high temperatures, when the binding agent decomposes between 392 and 752 ° F (200 and 400 ° C) due to the increase in temperature, it provides a source of acids; the binder being bound becomes acidic. The reaction of the acid source with the active aggregates of the binding agent produces gases such as carbon dioxide (CO2), water vapor, oxygen, hydrogen, and water, which are released in gaseous form in front of the ignition source, acting as a gasifying or blowing agent (gas source) to generate the rigid thin layer of multicellular carbon.

[0042] Conventional intumescent coatings, which generate a foamy, carbonaceous layer that grows 50 to 100 times their dry thickness, expand with increasing temperature. This carbonaceous layer absorbs heat and thermally insulates the substrate from fire.

[0043] The composition of the fireproof, intumescent and water-repellent coating of the present invention produces a thin and rigid layer of multicellular carbon that is difficult to remove. The inventor of the present invention found that they can use a composition with different organic aggregates, based on carbohydrates that contain excess carbon, among them common carbohydrates, which can be suitably selected from one or more monosaccharide groups. An example would be saccharose, which contains natural isomers: Trehalulose => glucose to (1 ^ 1) fructose; turanose => glucose to (1 ^ 3) fructose (reducing diholoside); maltose => glucose to (1 ^ 4) fructose; leucrose => glucose to (1 ^ 5) fructose (reducing diholoside); isomal tulose (palatinose) => glucose to (1 ^ 6) fructose

[0044] (reducing diholoside).

[0045] The carbohydrates used in the present invention comprise at least one bond connecting the monosaccharides of the O-glucosiolic type. According to the present invention, the preferred carbohydrate is sucrose.

[0046] The carbohydrates used in the present invention decompose at an approximate temperature of 392 °F (200 °C), producing a thermal process that involves melting and decomposition; when the agglutinates become acidic with the increase in temperature, an inversion reaction of the sucrose will occur, separating its components of a glucose molecule and another of fructose, up to its melting point, transforming into a thin layer with a carbonaceous structure. Thus, carbonization is generated in a condensation process, eliminating water from the sucrose.

[0047] Transforming into a thin layer of carbonaceous structure and thermal protection, the material, expanded into a single layer created by an organic polymer in an intermediate pyrolysis sector, and the carbonaceous layer provides thermal insulation. A gas source absorbs heat energy during the expansion and thermal boiling process, forming bubbles that are released and burst on the surface. Gases such as water vapor, oxygen, hydrogen, and carbon dioxide (CO2) are released, managing to isolate the thermal conductivity of the carbonaceous layer before it stiffens. Wherein, the organic polymers contribute to the transformation of the thin layer of carbonaceous structure and, at the end of the boiling process, to its stiffening.

[0048] The amount of organic carbon source is representative of 0.2-2.5% based on the total weight of the composition of the fire-resistant, intumescent and water-repellent coating of the present invention, preferably 0.2-2.3% by weight, more preferably 0.4-2.5% by weight, even more preferably 0.3-2.1% by weight and even more preferably 0.3-1.8% by weight.

[0049] Organic polymers

[0050] The configuration of a fire-resistant, intumescent and water-repellent coating of passive fire-preventive technology, of the present invention, comprises suitable organic polymers, which require, but are not restricted to, organic polymers and polysaccharides, which may be one or a mixture of more than one different organic polymer.

[0051] The organic aggregates resulting from the acidification of the binders used in the present invention to prevent the spread of flames, require, without limitation, materials such as fillers, fibers, clays, flame retardant agents, and flame inhibitors, which directly affect the radical reactions and their gaseous phase; these aggregates with fireproof properties and characteristics protect and prevent the passage of atmospheric oxygen to the flame sector, these additive aggregates prevent the temperature from affecting the polymer, eliminating the carbonization cycle, modifying the molecular structure of the polymers and increasing the structural support of the rigid-drying multicellular carbonaceous thin layer during exposure to fire, modifying the decomposition chemistry;These endothermic processes are activated by flame-retardant additives that absorb the heat released during combustion, lowering the temperature and reducing the speed of flame propagation for certain times, preventing combustion.

[0052] These flame and smoke inhibitors, used in the present invention for a coating, insert variations in the molecules of the polysaccharides integrating. These agents do not maintain risks of migrations so their fireproof properties and characteristics are preserved for several years without any deterioration, in addition they do not alter the thermal durability of the polysaccharide polymers (like other retardant additives that require constant maintenance). In the composition of a fireproof, intumescent, and water-repellent coating of the present invention, the amount of suitable organic polymers, comprising organic polysaccharide polymers is representative between 0.2-2.9% based on the total weight of the composition, such as preferably 0.2-2.5% by weight, more preferably 0.3-2.4% by weight, even more preferably 0.3-2.9% by weight and even more preferably 0.2-2.1% by weight.

[0053] The fireproof, intumescent and water-repellent coating composition of passive preventive technology of the present invention comprises a suitable fireproof agent, which requires, but is not restricted to a group of minerals of volcanic origin present in the Earth's crust, a fireproof mortar based on rock wool, vermiculite and perlite or a mixture of more than one different suitable mineral.

[0054] In the fire-resistant, intumescent, and water-repellent coating composition of the present invention, the fire-retardant agent contributes to inhibiting combustion by affecting radical reactions, reducing its flammability and increasing its temperature. Through its refractory microspheres, these endothermic processes activated by the flame-retardant additives that absorb heat radiation form barriers to the passage of oxygen, avoiding the flame zone, interrupting the combustion cycle, and thus containing the thermal effects in the area.

[0055] In addition, it drastically reduces radiant energy levels from 2192 to 77 °F (1200 to 25 °C) in seconds, eliminating the progression of smoke and preventing the spread of fire, generating a layer of thermal insulation to the flames at high temperatures, thus maintaining the fire stability of the structural elements.

[0056] In the composition of a fire-resistant, intumescent, and water-repellent coating of the present invention, the amount of the fire-resistant agent is representative of 1%-4.7% based on the total weight of the configuration, preferably 1.1-3.8% by weight, more preferably 1-4.2% by weight, even more preferably 1.4-4% by weight and even more preferably 1.3-

[0057] 4.7% by weight.

[0058] In the passive preventative technology fire-resistant, intumescent, and water-repellent coating composition of the present invention, a gas source is generated, suitable for, but not restricted to, compositions containing a compound or set of compounds, which produce gases upon exposure to heat or flame.

[0059] These gases, generally water vapor, hydrogen (H), nitrogen (N), carbon dioxide (CO2), can be one or a mixture of them, function as a gas source to generate the structural support of a thin, rigid, carbonaceous, multicellular, sealing and rigid layer.

[0060] Gases are produced by the reactions of the organic acid source and the binding agent during fire exposure. Gas generation begins as the acid source decomposes above 347°F (>175°C) to form acids that react with the binding agent.

[0061] Gas sources include organic polymers, monomers, or monosaccharides, which may be one or a mixture of these. When exposed to increased temperature or fire, reactions occur with thermal decomposition at approximately 392°F (200°C).

[0062] In the composition of a fireproof, intumescent and water repellent coating of the present invention, a gas source is generated, which produces a flammable gas upon exposure to heat or fire. The carbon produced provides excellent resistance and thermal insulating protection once combustion has started, providing robust protection when exposed to high temperatures and extreme turbulent forces in any type of fire, whether it be a cellulosic type fire or a hydrocarbon type fire. Each thin, rigid, multi-cellular layer of 10 mil thick coating withstands temperatures from 1112 to 1832 ° F (600 to 1000 ° C). Each thin, rigid, carbonized, multi-cellular layer of difficult-to-remove coating protects one event or one fire, if only 2 layers of 20 mil thick coating were applied.A thin, rigid, multicellular coating layer would act as a backing to protect the substrate from reaching its critical creep temperature, keeping the temperature below 1000.4 °F (538 °C), maintaining the structural stability and strength of buildings.

[0063] The composition of a fire-retardant, intumescent, and water-repellent coating of preventive passive technology of the present invention comprises suitable thermosetting elastomers requiring, but not restricted to, silicones, polyurethanes, neoprenes, rubbers, which may be one or a mixture of more than one different thermosetting elastomer.

[0064] Elastomers are highly elastic and viscous polymers formed by long, chain-like molecules of carbon, hydrogen, oxygen, or silicon. Their chemical structures feature intermolecular crosslinks and are capable of recovering their original shape after being stretched. Thermosetting elastomers do not deform with increasing temperature or when exposed to fire, nor do they melt; they remain in a solid state. Before melting, they enter a gaseous state called sublimation.

[0065] High-performance thermosetting elastomeric polymers possess very high thermal stabilities. Thermoplastic polymers soften as temperature increases and become liquid (melt). In contrast, thermosetting elastomers reach temperatures of up to 1256 °F (680 °C). They possess fire-resistant properties and maintain the structure of the multicellular carbonaceous thin layer in a solid state that is difficult to remove, and do not allow the organic agents in the composition of the present invention to melt in the combustion zone during the intumescence process, without degrading when the flame-retardant agent mitigates the combustion cycle.

[0066] Thermosetting elastomers limit the degradation of organic agents to reduce heat radiation. Flammability is combined with the availability of oxidation of the volatiles produced during degradation, which produce cross-linking, resulting in the formation of charred residues. This restricts the access of volatiles that cool the condensed phase and the release of non-combustible gases, which dilute the gases from the pyrolysis of organic polymers. Internally, the boiling process generates the formation, growth, and displacement of bubbles that transport gases to the surface, preventing them from becoming trapped within the thin multicellular carbonaceous layer, producing a maximum layer of thermal insulation to prevent the spread of fire. This process prevents the fireproof coating from stiffening and also eliminates smoke emissions.

[0067] In the composition of a fire-resistant, intumescent and water-repellent coating of the present invention, the amount of thermosetting elastomers is representative between 22 - 37% by weight, based on the total weight of the composition, preferably 24 - 33% by weight, more preferably 25 - 36% by weight, even more preferably 26 - 34% by weight.

[0068] The composition for forming a generally aqueous, passive technology, flame-resistant, intumescent, and water-repellent coating of the present invention comprises a suitable organic adhesion promoter that requires, but is not restricted to, Opuntia ficus mucilage, obtained from cladodes which is a hydrocolloidal heteropoly saccharide with arabinose, galactose, rhamnose, and xylose residues as neutral sugars. In a preferred embodiment of the present invention, in the composition for forming a generally aqueous, passive technology, flame-resistant, intumescent, and water-repellent coating, the amount of an organic adhesion promoter is representative of 0.1-3.6% by weight based on the total weight of the composition, preferably 0.1-2.9% by weight, more preferably 0.2-3.1% by weight, even more preferably 0.3-3.4% by weight.

[0069] The composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous of passive technology comprises suitable water-repellent additives, which requires but is not restricted to water-repellent agents, ethyl vinyl acetate (EVA), polylactic acid (PLA), calcium stearate, sodium oleate siloxane, redispersible polymers, can be one or a mixture thereof, function as a concept of hydrophobicity.

[0070] When water and moisture enter a building, they cause various forms of damage, including destruction of the concrete by corrosion of the reinforcing steel, chemical corrosion, decreased thermal protection, degradation of building materials, cracks caused by expansion and contraction, freeze-thaw damage, rust stains, dampness, mold and mildew, salt efflorescence due to hydration and crystallization, and corrosion of metals. The fireproof and intumescent coating of the present invention, when applied as a thin, rigid layer to supporting steel and concrete structures, walls, floors, and slabs, protects them from moisture, preventing possible water leaks, and acts as an integral waterproofing agent by sealing pores and capillaries. Since it is made up of organic and inorganic components, it is not affected by the passage of time, preventing damage to buildings.

[0071] The composition for forming a generally aqueous, intumescent and water-repellent coating of passive technology of the present invention comprises one or more suitable reinforcing fibers, which require, but are not restricted to, a group of organic fibers and inorganic fibers. The long-chain synthetic polymeric fibers of the group of thermoplastics belonging to the family of D-leuphins-Polyolefins that originate from the polymerization of propylene derive in polypropylene (PP) and that are presented in three molecular structures isotactic, atactic and syndiotactic with the molecular formula (C3 He) n; [CH2=CH-CH3] n.

[0072] The composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of passive technology of the present invention, may comprise one or a mixture of more inorganic reinforcing fibers, suitable for the composition, for example, refractory ceramic fibers (RCF) that come from the mixture of aluminum or silica and other refractory oxides have glassy materials and insulating properties at high temperatures.

[0073] The composition for forming a generally aqueous, intumescent, water-repellent, and fire-resistant coating of passive technology of the present invention comprises a group of organic fibers and inorganic fibers that may be one or a mixture of more than one different reinforcing fiber, representatively between 0.2-4.1% by weight based on the total weight of the composition, preferably 0.3-3.5% by weight, more preferably 0.2-3.8% by weight and even more preferably 0.5%-3.3% by weight.

[0074] Description of the Figures

[0075] Figure 1 shows the characteristic intumescent layer formed by state-of-the-art products.

[0076] Figure 2 shows the characteristic intumescent layer formed by state-of-the-art products.

[0077] Figure 3 shows the characteristic intumescent layer formed by state-of-the-art products.

[0078] Figure 4 shows the characteristic intumescent layer formed by state-of-the-art products.

[0079] Figure 5 shows a thin, carbonaceous, multicellular, rigid, and fire-resistant layer that is difficult to remove produced by the coating effect of the composition of the present invention applied to a galvanized sheet.

[0080] Figure 6 shows a detail of a scratch in the thin, carbonaceous, multicellular, rigid, and fire-resistant layer that is difficult to remove, produced by the coating effect of the composition, which reveals the thin, rigid white reinforcement layer that protects the substrate after subjecting it to high temperatures.

[0081] Detailed Description of the Invention

[0082] In one embodiment, the present invention provides a water-based, passive fire protection coating with intumescent properties, manufactured and developed for the protection of non-burning materials such as concrete and steel, as well as supporting steel structures. The present invention provides a protective coating against the high temperatures of a fire, to prevent the loss of properties and stability in buildings.

[0083] In another embodiment, the present invention provides a water-based, passive fire protection coating with fire-resistant properties. It is manufactured and developed for the protection of flammable materials such as wood, fiberglass, drywall, recycled PET panels, cardboard, and Styrofoam. It is a protective coating that shields them from high temperatures in a fire, thus preventing them from losing their properties.

[0084] Conventional intumescent paints of the state of the art mostly only protect metal supporting structures made of steel, being the primary objective for which they are manufactured.

[0085] In another embodiment, the present invention provides a water-based passive fire preventive protection coating with thermal insulating properties; by each rigid sealant thin layer, with a thickness of 10 thousandths of an inch (0.254 mm), exposed to high fire temperatures, it withstands temperatures of up to 2012 ° F (1100 ° C), for each applied layer, it does not allow flames or smoke to penetrate, it does not allow heat transfer after the fire. The rigid multicellular carbonaceous sealant thin layer, difficult to remove at 2012 ° F (1100 ° C) of temperature drastically reduces radiant energy levels up to 77 ° F (25 ° C) in seconds, completely isolating the fire area and maintaining its structural integrity. Conventional intumescent paints of the state of the art when exposed to heat or fire generate carbonaceous layers that expand 50 to 100 times their dry thickness.This carbon foam is porous, soft, and brittle, with inadequate resistance to withstand the turbulence of cellulosic and hydrocarbon fires.

[0086] Each difficult-to-remove multicellular carbonized rigid thin layer of the present invention protects against a fire with temperatures of 1112 to 2012 ° F (600 to 1100 ° C) for 60 or up to 90 minutes, providing time for evacuation. By applying 2 layers of 20 mil (0.5457 mm) coating, one thin layer supports the fire front and the other thin layer remains as a backup to protect the substrate, keeping the temperature below 1000.4 ° F (538 ° C) preserving the stability, insulation and structural resistance of buildings. The fireproof, intumescent and water repellent passive fire protection coating composition of the present invention can be applied over any substrate without the need to apply a primer or base coat adhered to the substrate. In particular, in buildings constructed with steel structures where conventional paints do not easily adhere to said steel structures.

[0087] Conventional intumescent paints of the state of the art, according to application specifications of paint or coating thicknesses of 39.37 to 196.85 thousandths of an inch (1 mm to 5 mm) once cured, when exposed to high temperatures in the face of fire, all applied layers are carbonized in a certain time to contain the fire, but there is no backing layer protecting the substrate, compromising the structural stability of buildings.

[0088] Each difficult-to-remove multicellular carbonized rigid thin layer provided by the present invention withstands the extreme turbulent forces in a hydrocarbon fire and is subjected to high temperatures of the magnitude of 2100 ° F (1093 ° C) in accordance with the international hydrocarbon fire standard UL1709, and also has sufficient thermal insulation capacity to protect the substrate with maximum adhesion. In accordance with the present invention, the fireproof, intumescent and water-repellent composition can be applied in more than two layers to form coatings with required fire protection times of at least 3 or 4 hours, based on the fact that each rigid thin layer withstands 2100 ° F (1093 ° C) for each hour. In these cases, for the application between one layer and another, the use of any element such as a support mesh applied between each layer is not required, as occurs in the prior art.In one embodiment, the present invention provides a fire-resistant coating of rigid thin layers, with a vitreous quartz mineral finish that withstands extreme weather conditions outdoors, such as sun, rain, wind, UV rays, dust, humidity, water vapor, and snow; it does not crystallize, erode, peel, or disintegrate due to its high adhesion properties.

[0089] With conventional state-of-the-art intumescent paints, if the product is applied outdoors, a finishing additive, such as gloss or varnish, must be applied to improve the properties of the exterior intumescent paints, and this equates to additional expense, increasing application costs.

[0090] The fireproof coating of the present invention is non-toxic, does not contain the presence of heavy metals such as: Arsenic (As), Cadmium (Cd), Chromium (Cr), Mercury (Hg), Lead (Pb), Antimony (Sb), Selenium (Se), and is also free of halogenated compounds and additives such as: Fluorine (F), Chlorine (Cl), Bromine (Br), and Iodine (I).

[0091] In conventional intumescent paints of the state of the art, these compounds or additives are common in several of their base formulations, it can be one or a mixture of them, these substances are effective solutions for thermoplastic materials against fire, but there is pressure from environmental and ecological groups for the use of halogenated groups, this causes the development of regulations in Europe that prohibit the use of these substances. Currently, there is a need to replace these substances with compounds that do not generate pollution and toxicity and that are free of halogens and heavy chemicals.

[0092] The fireproof and intumescent coating of the present invention is water-based and is configured with aggregates and organic and inorganic raw materials, of mineral and vegetable origin, fruits, free of heavy metals, are non-toxic, do not generate toxic fumes, all embodiments of the present invention are environmentally friendly in their manufacturing process.

[0093] The present invention provides a boiling process, produces the release of non-combustible gases, generates the formation, growth and displacement of bubbles that transport the gases to the surface, this endothermic process prevents the coating from developing carbonaceous expansion, inhibits it, it is not essential for a fireproof coating to become swollen, produces a thin, rigid, multicellular carbonaceous sealing layer that is difficult to remove, does not generate toxic fumes, encapsulates the fire and prevents the spread of flames by means of compartmentalization.

[0094] Conventional intumescent paints of the state of the art, mostly when exposed to increased temperature or fire, the acid source decomposes and the carbonization agent such as polyhydroxylated alcohols like pentaerythrityl tol, form a carbon, the flammable gases released by the blowing agent are retained in the film and are used to generate a spongy layer, which expands 50 to 100 times its dry thickness, this carbonaceous layer is porous, soft and fragile with inadequate resistance to face the turbulence of fires.

[0095] The present invention advantageously provides water-repellent properties, by means of hydrophobicity it prevents the rise and reach of moisture, the binding agent contains silicate mineral groups and natural quartz elements, this mineral is used to form a microscopic network of crystals in the capillary porosities of the fire-resistant coating, preventing water filtration and in turn unexpectedly prevents crystallization of thawing.

[0096] The present invention provides unexpected physical properties, the fibers serve to reinforce the fireproof coating, its main function is to reduce cracks caused by contraction in the pre-set and set states, it prevents micro cracks in tension states of traction, bending and torsion, it reinforces the applied layers keeping them rigid and drying, against high temperatures and fire containment, it reinforces the multicellular carbonaceous layer which is difficult to remove.

[0097] The present invention provides a composition for forming a fireproof, intumescent, and water-repellent coating with properties and technology for preventive passive fire protection with unexpected properties. Said composition, which is water-based, is manufactured and designed to protect load-bearing steel structures in mixed buildings, on walls, floors, and between floors; against fire, by means of rigid thin layers. It provides excellent resistance and thermal protection that generates a thermal insulating barrier against the ignition source, and once combustion has started, it provides robust protection when exposed to high temperatures and extreme turbulent forces in any fire generated by either cellulosic or hydrocarbon fire.

[0098] In one embodiment, the present invention provides a fire-resistant, intumescent and water-repellent coating system that unexpectedly has high values ​​in thermal protection; in each thin, rigid layer applied, it does not come off or disintegrate due to its high adhesion properties to the substrate and between each applied layer it protects it against exposure to a cellulosic fire, generated in front of a combustion source of materials such as steel, concrete, wood, paper, plastics, cardboard, textiles, plaster panels, Styrofoam, etc.

[0099] According to international standards, cellulosic fire is subjected to temperatures ranging from 1000 degrees °F (538 °C) to 1200 °F (649 °C) the steel does not burn, but in a fire, the steel heats up and loses structural strength in the first 10 minutes after a fire starts.

[0100] The present invention provides a fireproof, intumescent and water-repellent coating system with unexpectedly high values ​​in protection, cohesion, resistance, thermal protection in each rigid thin layer applied. In addition, it has a natural vitreous finish that does not crack, does not come off, does not disintegrate, due to its high adhesion properties to the substrate and between applied layers, protecting the substrate against exposure to a hydrocarbon fire, this same one that is generated in front of the combustion source when a fuel leak occurs, be it gas, oil, gasoline, diesel, hydrosine, jet A, turbosine, kerosene, diesel, etc.

[0101] These fuels spread in seconds; they rupture in pipelines, conduits, and other critical materials, spilling and catching fire immediately, causing puddle fires and burst fires in marine and terrestrial environments, as well as in oil and gas facilities.

[0102] Safe, instant, and effective fire protection solutions are needed that overcome the shortcomings of conventional, state-of-the-art coatings. According to the international standard UL1709, hydrocarbon fires are subjected to temperatures ranging from 2100°F (1149°C) in 5 minutes according to test curves.

[0103] Conventional state-of-the-art intumescent paints, when applied to steel structures for building construction, have a dry thickness of 4 to 8 millimeters upon curing, depending on the structure. When exposed to high temperatures, these paints expand their thermally insulating carbonaceous layer 50 to 100 times its thickness above 482 °F (250 °C), which retards the heating of the steel for a defined period of 60 to 120 minutes of protection.

[0104] Therefore, conventional intumescent paints of the state of the art keep the steel temperature below 932 °F (500 °C), protecting the resistance of the steel when a fire starts, its carbonaceous layer is fragile in the face of fire turbulence, in addition, all layers applied according to their required thickness are carbonized at the same time, at the time of their expansion and protection against fire.

[0105] In one embodiment, the fireproof, intumescent and water repellent coating of the present invention can provide at least a first rigid thin layer, 0.2524 mils (0.006411 mm) thick that supports 1652 to 2192 ° F (900 to 1200 ° C), at determined times of 60 minutes for each thin and rigid layer, to protect the substrate by means of its excellent adhesion properties and guaranteeing the stability of the steel or other construction materials and at least a second rigid thin layer exposed to fire that does not allow heat transfer, keeping it below its critical yield temperature, of less than 932 ° F (500 ° C), even with high temperatures of up to 2012 ° F (1100 ° C).

[0106] By applying the coating of the present invention, steel and other construction materials are protected in the event of a high-temperature fire, maintaining their stability and preventing them from collapsing, within specific times of 30 to 240 minutes, by means of its rigid thin coating layers, preventing the spread of flames to other adjacent areas where the essential thing is that the start of the fire is contained at the place where it started and is mitigated there by encapsulating the fire without generating toxic fumes. If also applied to walls and ceilings, it delays, mitigates and minimizes the effects of fire in any mixed building, protecting real estate and, as a main objective, safeguarding people's lives.

[0107] The composition for forming the fireproof, intumescent and water-repellent coating with properties and technology for passive preventive fire protection of the present invention comprises a combination of the following components: a) a dehydrating agent, b) a binding agent, c) a source of organic acid, d) a source of organic carbon, e) organic polymers, f) a fireproof agent, g) thermosetting elastomers h) an organic adhesion agent, i) a resin agent, and j) a fiber agent.

[0108] The composition for forming a fireproof, intumescent and water-repellent coating, using passive technology, of the present invention, comprises a suitable dehydrating agent, which requires, but is not restricted to, a group of fibrous metamorphic minerals, which occur naturally, are composed of double-chain silicates, complexes of iron, aluminum, sodium and magnesium mainly and are classified into two groups: amphiboles and serpentines, the amphiboles are a set of minerals from the silicate class, inosilicate subgroup, metasilicates of calcium, magnesium and iron.

[0109] Amphibole mineral components, Amphibiolites are mafic igneous rocks, contain equal amounts of hornblende and plagioclase or ultramafic rocks rich in highly magnesian amphibole, also contain minor amounts of mica, quartz, epidote, anthophyllite and garnet, the rocks originate from pelitic sediments with amphibole in include green pyroxene.

[0110] The mineral components of serpentine, with magnesium silicates, especially olivine, pyroxenes and amphiboles, frequently appear associated with magnesite, chromite and magnetite, in addition to antigorite and fosterite (olivine) minerals. Its pH 5.5, the pH values ​​provide magnesium and silicon in the solutions, in the replacement of magnesium ions with other ions, these properties highlight it as a catalyst.

[0111] In one embodiment of the present invention, the dehydrating agent is selected from minerals that are part of the phyllosilicate group, a powder absorbent and a fireproof mineral clay, its great porosity stands out, and a mineral to prevent bacterial fermentation, one of its great characteristics is that it is excellent for absorbing liquids including water, solvents or hydrocarbon oils and as a containment barrier.

[0112] Such dehydrating agent comprises hydrated natural mineral acrylics in fiber or powder, complexes of sodium, iron, aluminum and magnesium, which are known to be non-toxic, non-corrosive, inert, and not hazardous to health or the environment, in addition to being 100% biodegradable. Its physical properties are longitudinal fibers of 1.3 m, 2.4 m, 4.7 m or powder, its dehydration temperature is between 752 and 932 ° F (400 and 500 ° C), its melting point between 2732- 3092 ° F (1500- 1700 ° C), and its tensile strength: 892.4-1283.7 Mpa (medium strength).

[0113] Other components or aggregates more commonly used and known in the art may optionally be included in the products of the prior art, such as catalyst-dehydrating agent, amines: multifunctional organic compounds derived from ammonia, aniline is a primary amine, diethylamine is a secondary amine, trimethylamine is a tertiary amine, alkyl amine groups propylylamine, primary: methanamine, ethanamine, cyclopentanamine, secondary: N-methyl-propan-1-amine, N-methyl-1-aminopropane-methylmethanamine, methylethanamine, methyl pentan-3-amine, tertiary: NN-dimethylethanamine, NN-dimethylaminoethane, aromatic: aniline, methoxyaniline, pyrrole, pyridine, UREA phosphate, melamine phosphate, monoammonium phosphate. This invention does not use them.

[0114] In a preferred embodiment of the present invention, the composition for forming a fire-resistant, intumescent, and water-repellent coating, generally aqueous, the amount of the dehydrating agent is representative between 8-% and 19% based on the total weight of the composition, preferably 9-16% by weight, more preferably 10-17% by weight, and even more preferably 10-14% by weight.

[0115] Prior art products comprise a suitable binding agent, requiring, but not limited to, the family of ortho-, meta-, and pyro-silicates. It is also used for any ester containing the chemical group such as tetramethyl ortho-silicate; silicate anions are often large polymeric molecules with a wide variety of structures, including chains and rings. This invention does not utilize them.

[0116] Natural quartz mineral is found within the group of minerals called silicates that contain elements of silicon and oxygen, which are found in the Earth's crust and mantle. The formula of quartz is SiO2 and its crystal structures melt at 1112 °F (600 °C). Silicates are minerals with the presence of Ortho silicate ion (SiO4). 4 -) which can be combined to form groups such as fosterite, fayerite, zircon, kaolinite, muscovite, quartz.

[0117] A binder can act as an additive capable of agglomerating a material and that can produce a force between the bonds of both, this binder can be found in liquid, solid or powder form, it forms a bridge, film or matrix formulating a chemical reaction to create the union between three vertices and others formulating a chemical reaction to create a structure formed by flat layers that provide the phyllosilicates with a foliated structure.

[0118] The dehydrating agent is a fireproof mineral clay, which, due to its enormous porosity, is an absorbent of liquids including water at the time that heat is generated and / or a temperature increase between 248 to 356 ° F (120 to 180 ° C), its main function in this process is the extraction of water from the binding agent, silicates with alkaline cations and anions or analogs to chains, such as sodium ortho-silicate and metasilicate, are quite soluble in water. They form several solid hydrates when crystallized from the solution. Silicates of cations, non-alkaline or with polymeric anions, layered and three-dimensional, generally have negligible solubility in water.

[0119] As water is removed and / or absorbed from the liquid silicate, the silicate becomes progressively more viscous, the removal of water will convert the silicate into a glass film, with a weight ratio of 3:2 and are better suited to act as a film binder, the lower alkaline content of a silicate in a 3:2 ratio provides less affinity for water.

[0120] Polymerization reactions occur when the pH drops below 10.7; silicates react with acidic compounds, crosslinking them to form polymers. The anions in solutions depend on the concentration, temperature, and several factors. When dissolved silicates are acidified, generally by decomposition at temperatures between 392 and 482 °F (200 to 250 °C), acids are produced that react with other aggregates in the fireproof coating.

[0121] The binding agent, when decomposed by heat or temperature increase, provides a source of acids, the aggregates being agglutinated become acidified and are exposed to the reaction of carbon dioxide (CO2) if not some compounds can be added to the silicate to induce polymerization, such as organic acids, esters or carbonates.

[0122] When dehydration of the silicate solution occurs by hydrolysis of the ester and neutralization of the solution, the binder reacts in the acid to form the acetate anion, being a carboxylate and is the base of the acid formed by the deprotonation of acetic acid, which is released which can change its pH value to acidic, between 2 and 3, it is a safe and environmentally friendly process.

[0123] Silicates dehydrated by esters harden as a result of hydrolysis reactions following the dispersion of the ester in the binder. The ester gradually hydrolyzes, forming a weak acid and an alcohol. The acid reacts with the silicate to form potassium and sodium salts, and the bonding of hydroxyl (OH) groups on the silicon results in gelation.

[0124] In another preferred embodiment of the present invention, in the composition for forming a fire-resistant, intumescent and water-repellent coating, generally aqueous, the amount of binding agent is representative between 46% and 61% based on the total weight of the composition, preferably 46-59% by weight, more preferably 49-60% by weight, even more preferably 48-61% by weight and even more preferably 48-56% by weight.

[0125] In another preferred embodiment of the present invention, the composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of passive technology comprises a source of acid, suitable, requires but is not restricted to producing acid or acids, when the coating of the present invention faces fire, the acid containing attached silicon, this family of compounds has the formula [SiO x (OH) 4-2 x] n A 2 3 Some simple silicic acids are found in divided aqueous solutions, such as meta-silicic acid (H2SiO3), ortho-silicic acid (H4SiO4, PK al = 9.84, PK a2 = 13.2 at 77 °F (25 °C)), disilic acid (H2SiO5) and pyrosilicic acid (H6SiO2O7) in the solid state they condense forming polymeric silicic acids of complex structure.

[0126] Silicic acids can be obtained by acidifying silicate salts. In aqueous solution, the main problem is that silicic acids tend to be lost and form silica gel, a form of silicon dioxide. This conversion involves condensation processes.

[0127] The composition for forming an intumescent and water-repellent, generally aqueous, passive-technology fire-resistant coating of the present invention comprises a source of citric acid, an additive to silicic acid obtained by acidification of silicate salts. Citric acid is an organic tricarboxylic acid present in various citrus fruits, such as lemon, orange, and tangerine, and is obtained by aerobic fermentation of sugarcane mixture.

[0128] Carboxylic acids are very soluble in alcohols because they form hydrogen bonds with them. Furthermore, alcohols are not as polar as water. Long-chain acids are more soluble in them than in water; they have the general formula RCOOH and contain carbonyl and hydroxyl functional groups. Citric acid is a weak acid with a pH level between 3 and 6, the same as most organic acids.

[0129] The carboxyl group generates the molecule's polarity and the ability to form hydrogen bonds. The hydroxyl hydrogen can dissociate, and the compound acts as an acid, including methanoic acid, ethanoic acid, propanoic acid, and / or butanoic acid.

[0130] In a preferred embodiment of the present invention, the amount of the acid source is representative of 0.4 to 2.9% based on the total weight of the fire-resistant coating composition, preferably 0.4-2.2% by weight, more preferably 0.4-2.7% by weight, even more preferably 0.6-2.9% by weight, and even more preferably 0.5-2.5%.

[0131] The composition for forming a generally aqueous, fire-resistant, intumescent, and water-repellent coating with passive fire protection properties and technology of the present invention comprises a suitable organic carbon source, which is required, but not restricted, at the time the fire-resistant and intumescent coating is exposed to fire or high temperatures, when the binding agent decomposes between 392 and 752 °F (200 and 400 °C) by the increase in temperature, it provides a source of acids, the aggregates being agglutinated become acidic.

[0132] The reaction of the acid source with the active aggregates of the binding agent produces gases such as carbon dioxide (CO2), water vapor, oxygen, and hydrogen, which are released in gaseous form in front of the ignition source, acting as a gasifying or blowing agent (gas source) to generate the rigid thin layer of multicellular carbon.

[0133] In the state of the art, conventional intumescent coatings generate a foamy, carbonaceous layer that grows 50 to 100 times its dry thickness and expands with increasing temperature. This carbonaceous layer absorbs heat and thermally insulates the substrate from fire.

[0134] Unlike conventional intumescent coatings, the composition for forming a fire-resistant, intumescent and water-repellent coating, generally aqueous, of the present invention produces a thin, rigid layer of multicellular carbon that is difficult to remove. The inventor of the present invention formulated a composition with different organic aggregates, based on carbohydrates containing excess carbon, among them common carbohydrates, which can suitably be selected from one or more monosaccharide groups. Sucrose contains natural isomers: Trehalulose => glucose to (1 ^ 1) fructose; turanose => glucose to (1 ^ 3) fructose (reducing diholoside); maltose => glucose to (1 ^ 4) fructose; leucrose => glucose to (1 ^ 5) fructose (reducing diholoside); isomal tulose (palatinose) => glucose to (1 ^ 6) fructose (reducing diholoside).

[0135] Reactions with sucrose whose chemical name is a - D -Glucopyronosyl - ( 1 ^ 2 ) - pD- f ructof uranoside , its formula is C12H22O11, is a disaccharide of glucose and fructose, the molecule is diholoside formed by an a ( l <-> 2 ) p bond, its molar mass is 342.3 g / mol is formed by the union of two carbons at their reducing ends only the alpha anomer of glucopyranose and the p anomer of fructo furanose, the monoclinic crystal system according to the space group P21 with crystal parameters a = 1.08631nm, b = 0.87044nm and p = 102.938 ° .

[0136] Disaccharide carbohydrates generate reactions with sucrose composed of fructose and glucose molecules, including thermal decomposition, which occurs in two stages, dehydration by acids, which produce water and carbons C12H22O11 - ^ 12C + IIH2O and subsequent oxidation (with oxygen in the air of carbon to carbon dioxide -12C + 12O2 - ^ 12CO2 sucrose is carbonized does not melt when heated, it burns in an exothermic reaction to form water and carbon dioxide (CO2), with acids sucrose releases water, carbon dioxide and hydrogen chloride 8HCL O3 + C12 H22 On - ^ lllbO +12CO2 +8HC1.

[0137] The hemiacetal carbon of glucose and the hemiacetal carbon of fructose combine in the ionic bond, the hydrolysis of sucrose causes the rupture of the ionic bond releasing glucose and fructose in equimolar quantities. This reaction is very slow that in an aqueous solution of sucrose remains stable for years, but it can ferment or hydrolyze into fructose and glucose, In addition, this process can be controlled and prevented from crystallization, which allows its conservation. The carbohydrates used in the present invention comprise at least one bond that joins the monosaccharides that is of the O-glucosiolic type.In said dicarbonyl bond, the two reducing carbons of both monosaccharides form the alpha (1-2) bond of alpha-D-glucose and beta-Df ructuose, can be selected from one or more groups: beta-Df ructofuranosyl-alpha a- D-glucopyranoside, al f aD-glucopyranosyl-beta-D- f ructof uranoside, aD-glucopyranosyl- (1 ^ 2) - pD-fructo furanoside; BD-fructo furanosyl- ( 2 ^ 1 ) aD-glucopyranoside; B- ( 2S , 3S , 4S , 5R) - f ructof uranosyl- a- ( IR, 2R, 3S , 4S , 5R) glucopyranoside; a (IR, 2R, 3S, 4S, 5R)-glucopyranosyl-B-.

[0138] (2S, 3S, 4S, 5R) - fructo furanoside; (2R, 3R, 4S, 5S, 6R) -2

[0139] [(2S,3S,4S,5R)-3,4-dihydroxy-2,5-bis(hydroxymethyl)oxapent

[0140] -2-yl]-oxy 6-(hydroxymethyl)oxahexane.

[0141] The carbohydrates used in the present invention decompose at an approximate temperature of 392 ° F (200 ° C), producing a thermal process that involves melting and decomposition. Configured with different additional organic aggregates, with the increase in temperature an inversion reaction of sucrose will occur, separating its components of a glucose molecule and another of fructose. At its melting point, it transforms into a thin layer with a carbonaceous structure, generating carbonization in a condensation process eliminating water from the sucrose. Transforming into a thin layer of carbonaceous structure and thermal protection, the material, expanded from a single layer created by an organic polymer in an intermediate sector of pyrolysis and the carbonaceous layer, the gasifying agent absorbs heat energy during the expansion and thermal boiling process forming bubbles that release and burst on the surface.Gases such as water vapor, oxygen, hydrogen and carbon dioxide (CO2) are able to isolate the thermal conductivity of the carbon layer before it stiffens.

[0142] In the products of the state of the art, other components or aggregates more commonly used and known in the art can optionally be included, such as a carbonizing agent, carbohydrates, polyfunctional alcohols such as: sorbitol, pentaerythritol, dipentaerythritol, tripentaerythritol, resorcinol, polyvinyl alcohol, starch, cellulose powder, hydrocarbon resins, chloroparaffins, polyphosphates, which this invention does not use.

[0143] In a preferred embodiment of the present invention, the amount of organic carbon source is representative of 0.2-2.5% based on the total weight of the fire-resistant, intumescent and water-repellent coating configuration of the present invention, preferably 0.2-2.3% by weight, more preferably 0.4-2.5% by weight, even more preferably 0.3-2.1% by weight and even more preferably 0.3-1.8% by weight.

[0144] The composition for forming a generally aqueous, fire-resistant, intumescent, and water-repellent coating for passive fire prevention technology of the present invention comprises suitable organic polymers, requiring, but not limited to, organic polysaccharide polymers. It may be one or a mixture of more than one different organic polymer.

[0145] In a preferred embodiment of the present invention, the organic addition polymers can be one or a mixture of more than one different organic polymer suitable for forming a flame-retardant and intumescent coating. Polymerization occurs when a catalyst initiates the reaction. This catalyst cleaves the double carbon bond in the monomers. The monomers subsequently bond with one another due to free electrons, thus concentrating the bond until the process is complete.

[0146] Polymers are formed by organic monomers, these are not exempt from suffering combustion, when a polymer is calcined a thermooxidative reaction is generated that reduces the organic chains of the polymer to monomers of a minimum molecular weight, and in turn gases such as water vapor, hydrogen, carbon dioxide (CO2), and other ignition aggregates are released.

[0147] The increase in temperature causes thermal degradation, contributing to the growth of flames, the temperature of combustion during the boiling process and the formation of bubbles that release gases and break on the surface.

[0148] Inside, the polymer continues to degrade until a flame-retardant agent limits the carbonization of the polymer. This proceeds through the release of volatile agents and the access of oxygen to the ignition sector. Additives, fillers, fibers, and flame-retardant agents form physicochemical barriers, and their effectiveness depends on several factors, such as the state of interaction and dispersion with the polymer.

[0149] Ignition begins when the gases originating from the pyrolysis of the polymer and atmospheric oxygen combine, reaching a maximum internal temperature of around 1022 °F (550 °C). The reaction of the combustible gases with oxygen is exothermic, and the endothermic energy of the pyrolysis reaction causes the fire to spread.

[0150] In another embodiment of the present invention, the organic aggregates used to prevent the spread of flames require, but are not limited to, fillers, fibers, clays, and flame-retardant agents, flame inhibitors, which directly affect radical reactions and reactions in the gaseous phase. These aggregates, with their flame-retardant properties and characteristics, protect and prevent the passage of atmospheric oxygen to the flame sector. These additive aggregates prevent temperature from affecting the polymer, eliminating the carbonization cycle, modifying the molecular structure of the polymers, and increasing the structural support of the rigid-sealing multicellular carbonaceous thin layer during exposure to fire, modifying the decomposition chemistry.These endothermic processes are activated by flame-retardant additives that absorb the heat released during combustion, lowering the temperature and reducing the speed of flame propagation for specific periods of time, preventing combustion.

[0151] The flame and smoke inhibitors used in the present invention for a coating insert variations in the polysaccharide molecules. When integrated, these agents do not maintain the risk of migration, so their fireproof properties and characteristics are preserved for several years without any deterioration. In addition, they do not alter the thermal durability of the polysaccharide polymers (like other retardant additives that require constant maintenance). The products of the state of the art may optionally include other components or aggregates more commonly used and known in the art, such as the thermosetting organic polymer. It may be a suitable resin with Epoxy functionality.It may be one or a mixture including (i) polyglycidyl ethers, derivatives of polyhydric alcohols, such as ethylene glycol, triethyl glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,5-pentanedol, 1,2,6-hexanetriol, hydrogenated bisphenol-A or hydrogenated bisphenol-F (ii) polyglycidyl ethers of polycarboxylic acids, epichlorohydrin with an aliphatic or aromatic polycarboxylic acid, succinic acid, terephthalic acid, glutaric acid, oxalic acid, dimerized linoleic acid, (iii) epoxy resins oxyalkene groups (iv) olefinically unsaturated alicyclic materials, such as epoxyalicyclic ethers, esters, (v) resins epoxy novolac, are prepared to react with an epihalohydrin that this invention does not use.

[0152] In a preferred embodiment of the present invention, in the composition for forming a generally aqueous fire-resistant, intumescent and water-repellent coating, the amount of suitable organic polymers comprising organic polysaccharide polymers, which may be one or a mixture of more than one different organic addition polymer, is representative between 0.2-2.9% based on the total weight of the configuration, such as preferably 0.2-2.5% by weight, more preferably 0.3-2.4% by weight, even more preferably 0.3-2.9% by weight and even more preferably 0.2-2.1% by weight.

[0153] In another preferred embodiment of the present invention, the composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of preventive passive technology comprises a suitable fireproof agent, which requires, but is not restricted to a group of minerals of volcanic origin present in the Earth's crust. The fireproof mortar based on rock wool, vermiculite and perlite can be one or a mixture of more than one different mineral. They are natural minerals from the rhyolite group. The basic composition is an aluminum silicate added with other compounds of iron, magnesium, basaltic rocks; extracted in open mines. They have the property of exfoliating when the temperature increases, their level of growth in exfoliation is 15 times their actual size, transforming the solid lumps of mineral into light porous particles that contain incalculable microspheres of air and water inside.

[0154] Mineral aggregates retain their exfoliated structure and withstand high temperatures under the action of fire, reaching their melting point of 2462 °F (1350 °C). The minerals are calcined during the endothermic boiling process, their water molecules form bubbles that release gases and break on the surface. Inside, the polymers and minerals degrade until the fireproofing agent limits the carbonization of the organic aggregates, forming physicochemical barriers, generating an airtight and thermally insulating film against the high temperatures of fire. The fireproofing agent acts as a lightweight additive in fireproof mortars.

[0155] In another preferred embodiment of the present invention, in the composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, the fireproof agent contributes to the objective of inhibiting combustion by affecting radical reactions, decreasing its flammability and temperature increase, by means of its refractory microspheres. These endothermic processes activated by the fireproof additives that absorb caloric radiation form barriers to the passage of oxygen, avoiding the area of ​​​​the flames, interrupting the combustion cycle, containing the thermal effects in the area. In addition, it unexpectedly drastically reduces radiant energy levels from 2192 to 77 ° F (1200 to 25 ° C) in seconds, eliminating the progression of smoke and preventing the spread of fire. It generates a layer of thermal insulation to the flames at high temperatures, maintaining the fire stability of the structural elements.In another preferred embodiment of the present invention in the composition for forming a fire-resistant, intumescent and water-repellent coating, generally aqueous, the amount of the fire-resistant agent is representative between 1%-4.7% based on the total weight of the composition, preferably 1.1-3.8% by weight, more preferably 1-4.2% by weight, even more preferably 1.4-4% by weight and even more preferably 1.3-4.7% by weight.

[0156] In the composition for forming a generally aqueous, intumescent, and water-repellent coating of passive preventive technology of the present invention, a gas source is generated, suitable for, but not restricted to, compositions containing a compound or set of compounds that produce gas upon exposure to heat or flame.

[0157] These gases, usually water vapor, hydrogen (H), nitrogen (N), carbon dioxide (CO2), can be one or a mixture of them, function as a gas source to generate the structural support of a thin rigid multicellular carbonaceous sealing layer.

[0158] Gases are produced by the reactions of the organic acid source and the binding agent during fire exposure. Gas generation begins when the temperature at which the acid source decomposes increases to >347°F (>175°C) to form acids that react with the binding agent.

[0159] Gas sources include organic polymers, monomers or monosaccharides, which can be one or a mixture thereof, when exposed to increased temperature or fire, reactions occur with thermal decomposition at approximately 392°F (200°C).

[0160] Dehydration by acids that produce water, carbons and oxidation with oxygen from the air or carbon dioxide (CO2) and water, configured with different additional organic aggregates, decompose to release gases.

[0161] The composition of a fireproof, intumescent, and water-repellent coating contains an organic carbon source, which can be a solid or liquid carbon source, or a combination of both. These polymers are used as a gas source when exposed to fire and react with the acid source.

[0162] This organic carbon source forms a thin layer of rigid, sealing multicellular carbonaceous structure with an expansion of up to 10 times its dry thickness, when it reaches a temperature between 392 and 572 °F (200 and 300 °C).

[0163] Gasification produces the release of non-combustible gases. Internally, the boiling process generates the formation, growth, and displacement of bubbles that transport gases to the surface, preventing them from becoming trapped within the carbonaceous layer. This process prevents the coating from developing conventional intumescence; it is not essential for a fireproof coating to swell.

[0164] In another preferred embodiment of the present invention, the generally aqueous, intumescent, water-repellent, and fire-resistant coating-forming composition generates a gas source, which produces a flammable gas upon exposure to heat or fire. The carbon produced provides excellent strength and thermal insulating protection once combustion has started, providing robust protection when exposed to high temperatures and extreme turbulent forces in any type of fire, whether a cellulosic type fire or a hydrocarbon type fire. Each 10 mil thick, rigid, multi-cellular thin layer of coating withstands temperatures of 1112 to 1832°F (600 to 1000°C). Each rigid, multi-cellular, carbonized, hard-to-remove thin layer of coating protects against an event or fire.If only 2 layers of 20 mil thick coating were applied, a thin rigid multi-cellular coating layer would remain as a backup to protect the substrate, preventing it from reaching its critical creep temperature, keeping the temperature below 1000.4 °F (538 °C), maintaining the structural stability and strength of the buildings.

[0165] Conventional intumescent coatings of state of the art products, when exposed to increased temperature or fire, the acid source decomposes to form an acid and the carbonization agent forms carbon by means of forming agents such as polyhydroxylated alcohols such as pentaerythritol or dipentaerythritol, the carbon is obtained by decomposition of the polyhydroxylated alcohol, the flammable gases released by the blowing agent are retained in the film and are used to form the carbon and generate a spongy layer that can expand 50 to 100 times its dry thickness, which insulates and protects the substrate in certain times that are not used in this invention.

[0166] The carbonaceous layer of traditional state-of-the-art coatings mostly comprises applied layers of coating typically 1 to 8 millimeters thick. All of these layers carbonize in the event of a temperature increase or fire exposure, exposing the substrate, as no protective layer remains attached to the substrate.

[0167] After the protection period, the carbon layer of traditional state-of-the-art coatings mostly loses its adhesion, thermal insulation, and structural integrity. The residue of this porous foam is soft and brittle, with inadequate resistance to fire turbulence.

[0168] The products of the prior art may optionally include other components or aggregates more commonly used and known in the art such as melamine derived blowing agents are known in the art, melamine cyanorate, melamine (mono) phosphate, dimelamine phosphate, melamine biphosphate, melamine pyrophosphate, melamine polyphosphate, melam (1,3,5-triazine-2,4,6 triamine- n- (4,6 diamino-1,3,5-triazine-2-yl), melem (2,5,8-triamino- 1,3,4,6,7,9,9b-heptaazaphenalene), methiolated melamine, hexamethixelamine which this invention does not use.

[0169] The composition for forming a generally aqueous, passive technology, fire-resistant, intumescent, and water-repellent coating of the present invention comprises suitable thermosetting elastomers requiring, but not restricted to, silicones, polyurethanes, neoprenes, rubbers, which may be one or a mixture of more than one different thermosetting elastomer.

[0170] Elastomers are highly elastic and viscous polymers formed by long, chain-like molecules of carbon, hydrogen, oxygen, or silicon. Their chemical structures feature intermolecular crosslinks and are capable of recovering their original shape after being stretched.

[0171] Thermosetting elastomers do not deform or melt when exposed to heat or when exposed to fire. They remain solid. Before melting, they enter a gaseous state called sublimation.

[0172] High-performance thermosetting elastomeric polymers possess very high thermal stabilities. Thermoplastic polymers soften as temperature increases and become liquid (melt). In contrast, thermosetting elastomers reach temperatures of up to 1256 °F (680 °C). They possess fire-resistant properties and maintain the structure of the multicellular carbonaceous thin layer in a solid state that is difficult to remove, and do not allow the organic agents in the composition of the present invention to melt in the combustion zone during the intumescence process, without degrading when the fireproof agent mitigates the combustion cycle.

[0173] Thermosetting elastomers limit the degradation of organic agents to reduce heat radiation. Flammability is combined with the availability of oxidation of the volatiles produced during degradation, which produce cross-linking, resulting in the formation of charred residues. This restricts the access of volatiles that cool the condensed phase and the release of non-combustible gases, which dilute the gases from the pyrolysis of organic polymers. Internally, the boiling process generates the formation, growth, and displacement of bubbles that transport gases to the surface, preventing them from becoming trapped within the thin multicellular carbonaceous layer, producing a maximum layer of thermal insulation to prevent the spread of fire. This process prevents the fireproof coating from stiffening and also eliminates smoke emissions.

[0174] In the composition for forming a generally aqueous, passive technology, fire-resistant, intumescent, and water-repellent coating of the present invention, the amount of thermosetting elastomers is representative of 22-37% by weight, based on the total weight of the composition, preferably 24-33% by weight, more preferably 25-36% by weight, even more preferably 26-34% by weight.

[0175] The composition for forming a generally aqueous, passive technology, fire-resistant, intumescent, and water-repellent coating of the present invention comprises a suitable organic adherent substance, which requires, but is not restricted to, the mucilage of Opuntia Ficus, obtained from cladodes which is hydrocolloidal and heteropolysaccharide with residues of arabinose, galactose, rhamnose and xylose as neutral sugars.

[0176] Once cured and applied the coating on steel structures and other substrates, when exposed to fire, a decomposition of dehydrating agents occurs between 248 and 356 °F (120 and 180 °C), these mineral clays extract the water contained in the binding agent and the mucilage of Opuntia Ficus once dehydrated this viscous vegetable substance, acts as an organic additive adhesive.

[0177] The water extracted from the agents helps the exothermic boiling process, for the formation of bubbles that release gases and burst at the surface. Inside the fireproofing agent limits the carbonization of organic aggregates to reduce heat radiation, producing a maximum layer of thermal insulation, to eliminate the progression of fire. It forms an adherent protective layer that reacts to the ignition source; if two thin layers of coating are applied, the protective layer adheres between the multicellular carbonaceous layer and the rigid thin inner support layer, providing thermal protection, high adhesion properties that withstand extreme turbulent forces in a hydrocarbon fire. In addition, it has a natural vitreous finish, preventing it from reaching its critical creep temperature of 1000.4 ° F (538 ° C), maintaining its stability and preventing it from collapsing.

[0178] In a preferred embodiment of the present invention, in the composition for forming a fire-resistant, intumescent, and water-repellent coating, generally aqueous, of passive technology, the amount of an organic adherent substance is representative between 0.1-3.6% by weight based on the total weight of the composition, preferably 0.1-2.9% by weight, more preferably 0.2-3.1% by weight, even more preferably 0.3-3.4% by weight.

[0179] In one embodiment of the present invention, the composition for forming a fireproof, intumescent, and water-repellent coating, generally aqueous, of passive technology comprises suitable water-repellent additives that require but are not restricted to one or more water-repellent agents, ethyl vinyl acetate (EVA), polylactic acid (PLA), calcium stearate, sodium oleate siloxane, redispersible polymers. They can be one or a mixture thereof, they function as a concept of hydrophobicity, the ability of the substance to repel water, these additives act by forming a barrier that prevents the passage of water and the ions that accompany it.

[0180] When water and moisture enter a building, they cause various forms of damage, including destruction of concrete by corrosion of reinforcing steel, chemical corrosion, decreased thermal protection, degradation of building materials, cracks caused by expansion and contraction, freeze-thaw damage, rust stains, dampness, fungi and mold, salt efflorescence due to hydration, crystallization, and corrosion of metals.

[0181] The fireproof and intumescent coating of the present invention, when each rigid thin layer is applied to the load-bearing metal structures of steel and concrete, walls, floors and slabs, protects them from moisture, preventing possible water leaks, and acts as an integral waterproofing agent by sealing pores and capillaries. Since it is configured with organic and inorganic components, it is not affected by the passage of time, preventing damage to buildings. In a preferred embodiment of the present invention, in the composition for forming a fireproof, intumescent, and water-repellent coating, generally aqueous, using passive technology, the amount of a resin agent is representative between 0.2-3.7% by weight based on the total weight of the composition, preferably 0.2-2. 6% by weight, more preferably 0.3-2.3% by weight, and even more preferably 0.4-2.9% by weight.

[0182] The composition for forming a generally aqueous, intumescent and water-repellent coating of passive technology of the present invention comprises one or more suitable reinforcing fibers, which require, but are not restricted to, a group of organic fibers and inorganic fibers. The long-chain synthetic polymeric organic fibers of the group of thermoplastics belonging to the family of Dleufins-Polyolefins that originate from the polymerization of propylene derive in polypropylene (PP) and that are presented in three molecular structures isotactic, atactic and syndiotactic with the molecular formula (C3 He) n; [CH2=CH-CH3] n.

[0183] This structure provides the polymer with the highest degree of crystallinity (>50%) and gives polypropylene the PP fibers used as 100% virgin multifilament fibers used as secondary reinforcements in composite materials in fire-resistant coatings. They have a linear, semi-crystalline isotactic molecular structure with regular geometry and a helical shape, formed by long, complex aggregates of crystallites called spherulites.

[0184] The polypropylene used in the present invention is a non-toxic, environmentally friendly, corrosion-resistant plastic with a recycling category of plastics (PP) No. 5. It is approved for use in food, laboratory equipment, and medical applications.

[0185] The composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of passive technology of the present invention, may comprise one or a mixture of more inorganic reinforcing fibers, suitable for the composition, for example, refractory ceramic fibers (RCF) that come from the mixture of aluminum or silica and other refractory oxides have glassy materials and insulating properties at high temperatures.

[0186] In another embodiment of the invention, it may be preferred that in the composition for forming a fire-resistant, intumescent and water-repellent coating, generally aqueous, using passive technology, the fiberizing agent may be one or a mixture of more than one inorganic reinforcing fiber suitable for the composition. Glass fibers are composed of various metal oxides such as silica, alumina, lime, magnesium and inorganic mineral oxides. Type E glass reinforcing fibers, which are dielectric, are used for reinforcing type D composites in radars, and type R fibers contain high tensile strength and are used in the aeronautical and naval industries.

[0187] The main function of the synthetic inorganic polymeric fibers of the present invention is to reduce cracks caused by shrinkage, prevent micro fissures, prevent liquid filtration, avoid fractures in tension states of traction, bending, shear stress, torsion, provide maximum adherence to the aggregates and resistance to impacts that are dispersed over a multidirectional network to reinforce each applied rigid thin layer of the fireproof, intumescent and water-repellent coating.

[0188] The reinforcing fibers, which may be one or a mixture of more than one organic fiber and / or inorganic fibers, provide more resistance to wear and environmental degradation with extreme weather changes such as rain, sun, wind, UV rays, dust, humidity, water vapor, snow and prevents crystallization. It protects the natural vitreous finish of each applied rigid thin layer and eliminates the possibility of instability against high temperatures and fire containment. The microfibers according to the present invention may have a length of 12 mm to 75 mm, grouped in thermoplastic, aluminum, silica or glass monofilaments with a diameter of 16 to 35 (pm), with a breaking strength of 8.2 Kg, a length of 3 mm to 50 mm of each monofilament and an ignition point of 674.6 ° F (357 ° C).

[0189] Other components or aggregates such as inorganic fibers, carbon fibers such as boron carbide fibers, niobium carbide fibers, silicon carbon fibers, namely alumina-boron-silica fibers, E glass fibers (non-alkaline alumino borosilicate fibers), C glass fibers (non-alkaline or low alkaline soda lime-alumino borosilicate), A glass fibers (alkaline soda lime-silicate), mineral glass fibers, non-alkaline magnesia alumina silicate fibers, quartz fibers, silica fibers, high alumina-silica fibers, alumosilicate fibers, magnesia alumosilicate fibers, soda silicate fibers, polycarbosilane fibers, metal fibers, namely iron fibers, aluminum fibers, steel fibers, zinc fibers, etc., may optionally be included in the products of the prior art. These fibers can be formed by any physical or chemical process and any mixture thereof. This invention does not utilize them.In one embodiment of the present invention, the composition for forming a generally aqueous, intumescent and water-repellent coating of passive technology of the present invention comprises a group of organic fibers and inorganic fibers which may be one or a mixture of more than one different reinforcing fiber, representatively between 0.2-4.1% by weight based on the total weight of the composition, preferably 0.3-3.5% by weight, more preferably 0.2-3.8% by weight and even more preferably 0.5%-3.3% by weight.

[0190] Ethylene vinyl acetate (EVA) is a thermoplastic polymer made up of repeating units of ethylene and vinyl acetate, its semi-developed formula (C2H4) n (C4H6O2) m, is totally ecological and very light, it is a non-toxic and recyclable product very versatile, it is a polymer very close to elastomers in terms of flexibility, it can be processed like thermoplastics, being a thermoplastic elastomer.

[0191] Ethylene vinyl acetate (EVA) contains barrier properties, low temperature resistance, stress-cracking resistance, waterproof hot melt adhesive properties, UV radiation resistance and is odorless.

[0192] Ethylene vinyl acetate copolymer is an addition polymer formed by repeating units of ethylene and vinyl acetate.

[0193] The incorporation of vinyl acetate in the ethylene polymerization process produces a copolymer with a lower crystallinity than that of common ethylene homopolymer, therefore, these lower crystallinity resins have a lower melting temperature and heat seal temperature, and also reduce stiffness.

[0194] Calcium stearate is a water-repellent agent used in polymers, primarily PVC. It is a slip agent that has lubricating properties in plastics, acting as an acid scavenger or neutralizer, lubricant, and release agent due to its maximum resistance to water impregnation. Its formula Cae H70 Cg O4 is defined as the metallic salts of a fatty acid with an 18-carbon chain, known as stearic acid, such as metal oxides, metal hydroxides, metal sulfates, and metal chlorides.

[0195] Sodium oleate is a reactive hydrophobic agent, provides surface and mass protection, is an additive and is an organic compound, its chemical formula CIB H33 Na O2, sodium is the main component for the reaction of sodium hydroxide and oleic acid, which is an unsaturated fatty acid and is the most abundant fatty acid in nature.

[0196] Optionally, silane, a hydrophobic agent essential for bond strength in the cementation process, can be used in the present invention. It provides protection to the fireproof coating and increases resistance to water and weather, as well as the attack of chlorides, carbonation, and environmental pollutants. It is not a vapor barrier, allowing the wall to breathe. Its formula, SIH4, silicon hydroxide, decomposes into silicon and hydrogen above 788°F (420°C). It can be used in chemical vapor deposition of silicon.

[0197] Siloxanes are other hydrophobic agents; they are an organosilicon functional group with the Si-O-Si bond. They include oligomeric and polymeric hydrides. Their formulas H(OSiH2) n OH and (OSiH2) n, are the main part of silicones such as polyodimethyl siloxane of the RaSiO functional group called siloxy, are artificial and have several industrial applications due to their hydrophobic characteristics, low thermal conductivity and high flexibility.

[0198] Organic compounds formed by linear or cyclic chains of silicon, oxygen and methyl groups include high and low viscosity fluids, rubbers, elastomers and resins. Silicones are siloxane or polysiloxane polymers, a mixture of inorganic and organic polymers, whose chemical formula is [R2SIO] n, where R belongs to organic groups such as methyl, ethyl or phenyl.

[0199] Redispersible polymer powders, which can be optionally used in the present invention, are produced by spray-drying organic materials. They produce high adhesion resistance on vitrified and low-absorption materials, based on the application of thin layers of the coating. The redispersible powder is derived from the behavior of the particles upon contact with water; during hardening, elastic polymer bridges are created between the mineral components of the fire-resistant coating.

[0200] The polymer modification additionally confers flexibility to the system and improves thixotropy, fluidity and water retention, due to its hydrophobic impregnation.

[0201] The matrix of the crystallization resin agent composition consists of a mixture of calcium silicate, which, when reacted with a chemical base of amino alcohols and organic minerals dispersed along with the binding agent containing quartz minerals, becomes progressively more viscous. The removal of water absorbed by the dehydrating agent will convert the silicate into a vitreous quartz film on the exterior of each rigid, thin layer of fireproof coating.

[0202] Additionally, the dehydration and crystallization of the silicate is generated, converting the silica sand into microscopic quartz flakes. Together, the water-repellent agents are mixed with bituminous emulsions, waxes, fatty acids and butyl stearates, substances that allow lubrication, causing them all to slide through the internal capillary system of the fireproof coating, which inside the substances are activated and form invasive, non-soluble quartz crystals, which obstruct the entire microscopic capillary network, in any fissure up to 0.04 millimeters thick, preventing the filtration of water and moisture, drying the fireproof coating completely.

[0203] The composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of passive technology of the present invention, under the curing conditions, drying is at room temperature 64.4 - 86 ° F (18 - 30 ° C). As a priority, the coating is cured by physical drying in natural environmental conditions with the volatilization of water and organic aggregates present in the composition. To generate adequate setting, it is recommended from 24 to 36 hours depending on the temperature, to avoid lumps on the rigid surface for each thin rigid layer applied, until obtaining homogeneous setting and hardening.

[0204] Examples of application of the invention.

[0205] In a foundry, samples 1-4 were prepared, the fireproof, intumescent and water repellent coating containing the composition of the present invention was applied directly without primer, they were formed on the floor and the test consisted of the direct pouring of incandescent copper molten material with a temperature of 2264 ° F (1240 ° C). Sample 1 consisted of a square stainless steel plate of 300 mm x 300 mm and 10 mm thick. To this sample were applied 2 thin layers of coating with a total film thickness of 20 mils (0.508 mm).

[0206] Sample 2 consisted of a 200 mm x 200 mm square stainless steel plate, 10 mm thick. This sample was coated with 3 thin layers with a total film thickness of 30 mils (0.762 mm). Sample 3 consisted of a 200 mm diameter round stainless steel plate, 10 mm thick. This sample was coated with 4 thin layers with a total film thickness of 40 mils (1.016 mm).

[0207] Sample 4 consisted of a round stainless steel plate measuring 200 mm in diameter and 10 mm thick. No coating was applied to this sample.

[0208] Square and round stainless steel plates were coated by air spraying, and then allowed to dry at room temperature of 90°F (32.2°C). Curing time for each coat was at least 24 hours; after one week of curing, the pieces were optimally hardened and homogeneous. Samples 1-3 were coated on one side only with the fireproof, intumescent, and water-repellent coating containing the composition of the present invention.

[0209] Qualified personnel from the foundry poured the copper lava melt directly onto each of the faces of the samples, using the fireproof, intumescent, and water-repellent coating containing the composition of the present invention. A fire immediately erupted on each of the samples. After a few minutes, the fire subsided, and the copper hardened, forming a film on each sample. The copper film was subsequently removed within seconds, and the molten copper was released in a solid state.

[0210] The composition to form the fireproof, intumescent and water-repellent coating generated a thin, multicellular carbonaceous layer, difficult to remove, which had to be scraped with a tool (screwdriver) to remove it, which withstood in seconds the lava poured at a temperature of 2264 °F (1240 °C) and mitigated the fire that was generated.

[0211] The fireproof and intumescent coating, surprisingly, withstood the incandescence of the molten copper poured over it with a single thin layer and then, when it was removed, beneath this thin outer carbonaceous layer, the next rigid thin layer, white in color, continued, when what would be expected would be that the applied layers of the fireproof coating would immediately separate upon contact with the copper melt due to the incandescence.

[0212] This temperature resistance test of 2264°F (1240°C) was performed on the three steel samples mentioned above with different coating thicknesses. The same result occurred on each sample: the first thin outer layer charred.

[0213] After scraping samples 1, 2 and 3 and observing the following rigid thin layer in white, the fire-resistant coating surprisingly drastically reduced the temperature from 2264 to 77 °F (1240 to 25 °C) in less than 120 seconds, which was confirmed with a pyrometer, type K thermocouples and by touch on each steel plate.

[0214] Regarding sample 4 of round steel plate, which was not coated with fireproofing, the result was that the copper film was removed, but the plate remained stained with a black mark from the casting material. The temperature of the plate did not drop below 1328 °F (720 °C) as measured by a pyrometer and type K thermocouples during the first 30 minutes after the lava was poured and it was impossible to touch the piece, the heat radiation still remained, making it impossible to touch.

[0215] In another test, a wooden log is the test sample, with a length of 23.62 inches (600 mm) and a diameter of 7.08 inches (180 mm), the surface of the log was completely cleaned and dried at room temperature for 3 days at an approximate temperature of 82.04 to 89.6 ° F (28 to 32 ° C) to prevent it from containing moisture inside. The log was drilled using a drill and a 0.5 inch (12.7 mm) bit, at a height of 3.93 inches (100 mm) from the top down, to enter a thermocouple at 3.54 inches (90 mm) deep, towards the center of the wooden log in order to take the internal temperature of the log. In that position, the temperature was measured at 10-minute intervals with an additional pyrometer.

[0216] Once the sample was prepared, it was coated with a fireproof and intumescent coating, two thin, rigid, white layers were applied, where the two thin, rigid layers of white were applied over the entire surface of the sample, with a layer thickness of 10 thousandths of an inch (0.254 mm) each layer, by air spraying. For curing, 24 hours were required for each applied layer, for 20 thousandths of an inch (0.508 mm) 48 hours of curing were required and thus a homogeneous setting and hardening was achieved.

[0217] The sample was exposed to fire from a butane gas torch that generated a direct fire flame that was applied at a fixed point on its periphery. Thermocouples were fixed at the fixed point of application of the fire to measure the temperature increases. In a matter of 5 minutes the temperature reached 842 °F (450 °C) and in 10 minutes the temperature rose to 1895 °F (1035 °C), subsequently the exposure to fire and the temperature remained substantially stable.

[0218] In accordance with the present invention, the coating composition produced a carbonization process of the fireproof, intumescent and water-repellent coating in its applied rigid thin layers, when they were exposed to high temperatures in the first 10 minutes. The composition of the present invention did not allow flames or smoke to penetrate, nor did it allow heat transfer, completely isolating radiation by its rigid multicellular carbonaceous sealing thin layers. They were difficult to remove by instantly absorbing and repelling heat energy, withstanding temperatures of 1112 to 1940 ° F (600 to 1060 ° C) for a determined time of 60 to 80 minutes of fire protection, while the second rigid thin layer of 10 thousandths of an inch (0.254 mm) thickness provided insulation, stability and structural resistance to the wood sample, protecting it to prevent the flames from reaching the substrate.

[0219] As a result of the application of the composition in the coating of the present invention, it was surprisingly obtained that there was no high heat transfer and the temperature inside the wood log sample had extremely low variation values ​​not greater than 50 °F (10 °C) during time intervals that were from 5 to 10 minutes as seen in the following table. Such extremely low temperature variations were obtained despite the fact that the temperature on the outside of the wood log sample was at more than 1832 °F (1000 °C) in a total time interval of 80 minutes. This test showed that the thin rigid inner layer protects the substrate and provides thermal insulation, stability, tightness and resistance to the wood inside without generating smoke.

[0220] The first thin, multicellular carbonaceous layer, difficult to remove after removing the direct flame, which reached a temperature of 1940°F (1060°C), was also surprising because in the first 30 seconds thereafter it was reduced to the initial temperature of the test, which was corroborated simply and surprisingly by touch. To do this, we placed our hands on the wooden log and did not perceive the radiation of a burnt product, only warm-cold, touching it for 1 minute.

[0221] We then remove the thin, multicellular carbonaceous layer, which is difficult to remove. We remove it with a sharp tool (screwdriver) and scrape it hard. It scratches, is removed, and carbonization powder residue remains, but underneath remains the next thin, rigid, white layer of support to protect the wooden trunk.

[0222] The above exemplifies the benefits of the present composition made from organic aggregates such as vegetables, fruits, natural minerals and natural fibers, among others, to provide protection with the fireproof, intumescent and water-repellent protective coating and passive fire technology of the present invention, giving the opportunity to protect wooden posts, wooden houses, trees by protecting them from fire outbreaks and / or forest fires that occur when dry grass burns and spreads towards the trees, ending up losing trees that are 10-<50 years old.

[0223] Cardboard plates are the test samples used to test the performance and effectiveness of the composition to form a fireproof, intumescent and water-repellent coating, generally aqueous. Cardboard from an egg carton was used. It was cut to a size of 11.81 inches x 11.81 inches (300 mm x 300 mm) and 0.19 inches (5 mm) thick. The sample was prepared and coated with the fireproof, intumescent and water-repellent coating in two layers. A thin layer of the white fireproof, intumescent and water-repellent coating was applied with a film thickness of 10 mils (0.25 mm) by air spraying. For curing, 24 hours of drying at room temperature is required for each applied layer. Thus, for 20 thousandths of an inch (0.50 mm) 48 hours of drying were required to achieve optimal homogeneous rigid setting and hardening.The equipment used to perform the fire resistance tests was a pyrometer for measuring high temperatures up to 2912°F (1600°C), two pairs of type K thermocouples for measuring temperatures up to 2372°F (1300°C), where one pair of thermocouples measured the temperature of the coated surface on the front, while the other thermocouple measured the temperature on the back, which did not have any coating applied. Temperature readings were taken at 10-minute intervals.

[0224] Once the test sample was cured, the cardboard plate was coated on one side with the fire-resistant, intumescent and water-repellent coating, with a thickness of 20 mils (0.50 mm).

[0225] The test sample was subjected to temperature increase using a butane gas torch that generated a direct flame. The flame was concentrated at a fixed point and reached a temperature of 770°F (410°C) within 5 minutes. Within 10 minutes, it reached a temperature of 1427°F (775°C).

[0226] In the physical phenomenon of the carbonization process of the applied rigid thin layers of the fireproof, intumescent and water repellent coating of this invention, when exposed to high temperatures in the first 10 minutes and during the resistance test, they did not allow flames or smoke to penetrate the cardboard (substrate) preventing heat transfer. Heat radiation was completely isolated by means of its multicellular, sealing, difficult to remove, 10 thousandths of an inch (0.25 mm) thick carbonaceous thin layers, absorbing heat radiation, repelling it, supporting heat radiation with temperatures from 1427 to 1862.6 ° F (775 to 1017 ° C) for 60 minutes of protection against direct fire, while the second thin, rigid layer, 10 thousandths thick (0.25 mm) withstood the thermal insulation, tightness, stability and resistance of the cardboard plate (substrate), protecting it to prevent the flames from reaching said substrate. Surprisingly, the flames did not penetrate the uncoated back face, since there was no mark of heat transfer. We could place the palm of our hand even with the direct flame of the blowtorch at a distance of only 0.21 inches (5.5 mm), without perception that the heat radiation penetrated through the cardboard plate coated with the composition to form a fireproof, intumescent and water-repellent coating, generally aqueous of the invention. With this, there was assurance that the heat radiation did not pass. The cardboard sample withstood the test with a temperature of 1688 ° F (920 ° C), while on the back face there was a temperature of 77 ° F (25 ° C) taken with the thermocouple.

[0227] The temperature reading in the previous example is as shown in the following table.

[0228] This test showed that the first rigid thin layer protects the substrate and provides thermal insulation, stability, tightness and resistance to the cardboard plate without generating smoke.

[0229] On the back of the cardboard plate there was no transfer of heat radiation and in the temperature measured with the thermocouple there was a temperature variation of 42.8 °F

[0230] (6°C) within 1 hour.

[0231] The composition for forming a fireproof, intumescent and water-repellent coating, generally aqueous, of the present invention of passive, fire-preventive technology, is particularly suitable in its properties and technology that are intumescent, protect materials that do not burn but lose their original properties of rigidity and stability when subjected to high temperatures and / or fire directly, such as concrete and steel. It is manufactured and developed for the protection of load-bearing steel metal structures in the construction of buildings or houses and is applied in structures such as: pillars, columns, "I" and "H" type beams, girders, steel slab floors and floors, load-bearing walls, ceilings, partitions, walls and concrete walls, etc., guaranteeing the stability of buildings and limiting the development of fire to prevent their collapse.The fireproof, intumescent, and water-repellent passive fire protection coating composition of the present invention can be applied to any substrate without the need to apply a primer or base coat adhered to the substrate. In particular, in buildings constructed with steel structures where conventional paints do not easily adhere to said steel structures. Another property of the coating composition is that it is fireproof, protecting flammable materials such as wood, drywall, recycled PET panels, fiberglass, cardboard, polystyrene foam, among others, protecting them from high temperatures in the face of fire, in specific times of 30 to 240 minutes, by means of its thin, rigid, sealing layers, of application of the fireproof, intumescent, and water-repellent coating, preventing the spread of flames to other adjacent areas.The most important thing is to contain the fire at its source and mitigate it there without allowing it to spread to other areas, encapsulating the fire. When applied to walls and ceilings, it also delays, mitigates, and minimizes the effects of a fire, allowing time for evacuation with the primary objective of safeguarding the lives of living beings in general.

[0232] The passive, preventative technology fireproof, intumescent and water repellent coating composition of the present invention can be applied by brush, roller or spray and is applied in mixed buildings such as: hotels, hospitals, schools, shopping centers, cinemas, theaters, auditoriums, parking lots, restaurants, kindergartens, laboratories, prisons, clubs, canteens, factories, warehouses, industrial buildings, museums, galleries, churches, markets, supply centers, bus stations, government buildings, wooden houses, condominiums, automobiles, wooden poles, wind turbines, airplanes, hangars, rockets, spacecraft, satellites, railroads, racing and competition cars, batteries, ships, airports, refineries, chemical plants, gas plants, offshore platforms, petrochemical plants, trees (forest fires), etc.

[0233] The fireproof, intumescent, and water-repellent coating of the present invention also protects buildings that provide mixed services, places where we live, study, work, or play, which must be safe in the event of a fire. Its uses and applications also cover sectors such as the automotive, pharmaceutical, hotel, space, manufacturing, electrical, textile, food, petrochemical, aeronautical, gasoline and gas, mining, commercial, transportation, construction, fishing, industrial, educational, cultural, and other industries.

[0234] The present invention can also be presented as a rough-looking paste-type fireproof mortar that protects and maintains the stability of buildings in the event of a fire. It withstands temperatures of 1292 to 2012°F (700°C to 1100°C) for each thin, rigid layer applied, with a thickness of 0.2527 thousandths of an inch (0.25 mm), for required times of 3 to 4 hours and with a single thickness of 0.7581 thousandths of an inch (0.02 mm) dry thickness. Its installation is very clean and simple by means of a brush, roller or electric airless equipment, providing maximum adherence, providing aesthetics and finish to steel metal structures, walls, delaying, mitigating and minimizing the effects of flames.

[0235] Unlike fireproof cementitious mortars (cement-based, gypsum-based, vermiculite-based, or mineral wool-based), cement spraying is applied using pneumatic spraying machines. Cement spraying, depending on the project or structure, requires thicknesses of 0.39 to 1.96 inches (10 to 50 mm) according to the required protection, within specific time periods of 30 to 240 minutes, adding weight to the structures. It is available in 10- to 25-kilo sacks that are diluted in water.

[0236] In another embodiment, this invention is presented in powder form, without modifying its fire-resistant and water-repellent composition, now not providing passive protection but rather active fire protection, now facing a fire that has already started. The spray-drying process is known to be a refined method for drying solid substances from aqueous or organic solutions, suspensions, and emulsions, to produce consistent, precisely defined, functional dry powders with uniform density and robust agglomerates that are easily re-dissolved in water. The spray-drying processes are as follows:

[0237] Concentration: to reduce the amount of liquid you want to evaporate.

[0238] Atomization: to conduct a dry product that has the desired characteristic.

[0239] Air contact with droplets: The atomized liquid comes into contact with hot air in the drying chamber, resulting in water evaporation. The way the spray comes into contact with the impacted air influences the behavior of the droplets during the drying phase and directly affects the properties of the dried product.

[0240] Droplet Drying: Two-stage evaporation of moisture. The water that evaporates from the surface is replaced by more water molecules from the volume.

[0241] It begins when there is no longer enough moisture to maintain the saturated condition on the droplet surface.

[0242] It causes a dry layer to form on the surfaces, the evaporation rate decreases, and the layer increases in thickness. Separation:

[0243] Primary. Heavy particles simply fall to the bottom of the drying chamber; a small fraction of fine particles remain entrained in the air.

[0244] Secondary separation cyclone separator and electrostatic precipitator, final separation filter bags or wet scrubbers used to purify and cool air.

[0245] The powder, which can be obtained according to the above, provides an active protection extinguishing powder. It is a solid substance in a powdery state used for extinguishing fires. It is called dry powder, a multipurpose powder. Its composition is based on organic aggregates, minerals, and natural physical elements, which provide fire suppression properties that are extinguished by cooling the fuel. The molecules of the extinguishing agent absorb energy, which is transformed into an increase in temperature when changing to a vapor state and into the breaking of chemical bonds between its atoms.

[0246] According to the present invention, one embodiment thereof can be supplied as an extinguishing powder for extinguishing forest fires, for aerial spraying launched from airplanes and helicopters, being a solid substance active against fires in a powdered state, its configuration is based on organic aggregates obtained from vegetables, fruits, minerals and natural fibers.

[0247] According to the present invention, another embodiment thereof can be supplied as a fire extinguishing powder in the form of spheres, which is portable, lightweight, non-toxic, does not contain heavy chemicals, and is halogen-free. It is a solid substance active against fires in a powdered state, which is supplied in 1.0 kg spheres that help fight any type of fire, extinguishing it instantly within a radius of 3 square meters. In this case, there are two types of use, the first is automatic in the presence of a type A, B, or C fire, the sphere is automatically activated and will spread 360° degrees within said diameter of 3 square meters. The second use is manual, in which case, in the event of a fire, the sphere is thrown and it will extinguish instantly.

[0248] According to the present invention, another embodiment thereof can be supplied as a fire-extinguishing powder for loading fire extinguishers, being a solid substance active against fires in a powdered state. The extinguishers are steel containers pressurized with inert gas at 15 to 17 bars. The extinguishing powder consists of saline compounds, organic aggregates, minerals, and natural fibers. The composition of these aggregates creates a barrier that prevents the entry of oxygen. The universal extinguishing powder acts as a catalyst, inhibiting the combustion reaction and extinguishing the fire through its suppression effect.

[0249] According to the present invention, another embodiment thereof can be supplied as a universal extinguishing powder, which is a dry powder used to extinguish class A "combustible solids" fires, class B "combustible liquids and gases", class C "energized electrical equipment", being found in different presentations of 1 kg, 2 kg, 4.5 kg, 5 kg, 6 kg, 9 kg, 12 kg and others.

[0250] According to the present invention, another embodiment thereof can be supplied as an aerosol. In the fire-resistant and water-repellent composition of the present invention, the aerosol propellant is added. LPG gas is used to propel the substances contained in the aerosols. It dries quickly, and has a yield of 1 to 1.5 m 2 per can, it is kept at high pressure inside the canister, in a partially liquid state. The propellant is mixed with the liquid to be vaporized.

[0251] The purpose of this modality is to spray the vapor and not the liquid, so the valve is designed to capture the vapor from the top of the can, when shaking the can, turning it or flipping it, the valve is pressed and the sprayed liquid will be expelled.

[0252] According to the present invention, another embodiment thereof can be supplied as a fireproof and water-repellent composition of the present invention in the form of a silicone gun can. For this, additional organic and inorganic aggregates are required, which can be one or a mixture of more than one aggregate. Among them is the primary product for its configuration, which is silica (silicon dioxide), in addition to polymers that have in common a chain in which silicon (Si) and oxygen (O) atoms alternate, which are strongly linked by covalent bonds, each silicon atom being linked to two organic radicals.

[0253] Silicone is an odorless, colorless polymer composed primarily of silicon that is used to bond or seal materials and whose main virtue is that it maintains a certain elasticity once applied.

[0254] The transformation into elastic solids is achieved through the elastic polymer polymerization process. It is a thermoplastic adhesive for bonding surfaces such as wood, glass, cardboard, fine metals, porcelain, fiberglass, porcelain, or plastics when consolidated in a cylindrical container.

[0255] In accordance with the present invention, another embodiment thereof can be supplied as a gypsum panel, which is a lightweight material essentially made of gypsum, reinforced with strong fibers, covered on both sides with recycled paper for core protection. It is used on interior and exterior walls, in construction projects, remodeling, partition walls, and to protect walls and ceilings during construction projects. They are manufactured in a variety of standard lengths and thicknesses for use in construction, fire fencing, forest fire containment barriers, etc.

[0256] In accordance with the present invention, another embodiment thereof can be supplied as a cement panel which is a panel with a lightweight cement core between two layers of impact-resistant fiberglass mesh, which is used for the creation of exterior walls, facades, dividing walls, fire fencing, forest fire containment barriers, which are manufactured in a variety of standard lengths and thicknesses.

[0257] According to the present invention, another embodiment thereof can be supplied as a metal panel with an insulated core and exterior or interior steel cladding of composite systems for walls or roofs, facades, dividing walls, fire walls, forest fire containment barriers, which are designed in a variety of thicknesses and profiles, and standard lengths for use in construction.

[0258] According to the present invention, another embodiment thereof can be supplied as insulated panels with high levels of thermal insulation, manufactured with fiberglass, wood, cardboard, or polystyrene foam facings. These are lightweight panels used in construction projects for interior and exterior walls, partition walls, facades, dividing bars, fire fencing, and forest fire containment barriers; they are designed in a variety of standard lengths and thicknesses for use in construction.

[0259] All of the above fire containment walls are coated with the fireproof, intumescent and water-repellent coating of the present invention and feature passive fire prevention technology. The coating is applied by application or air spraying, in different film thicknesses depending on the construction work project according to the type of panel and its coating. The applied rigid thin layers of coating provide excellent resistance and thermal protection that generate a thermal insulating barrier against the ignition source and once combustion has started, providing robust protection when exposed to high temperatures and extreme turbulent forces in any fire generated by either a cellulosic type fire 1000°F (538°C) or a hydrocarbon type fire 2100°F (1149°C).

[0260] Each thin, rigid coating layer applied to the panels features a natural vitreous finish that won't crack, peel, or disintegrate due to its high adhesion properties to the substrate of each fire containment panel, protecting it from exposure during the spread of fires. These panels, formed into barriers, prevent the spread of fires.

[0261] Each thin, rigid coating applied to the containment panels protects them from moisture and acts as a comprehensive waterproofing agent by sealing pores and clogging the entire microscopic capillary network, preventing water and moisture infiltration. It also protects against wear and environmental degradation caused by extreme weather conditions such as sun, UV rays, wind, dust, rain, humidity, and low temperatures of 86°F (30°C) and snow, preventing crystallization.

[0262] The present invention is a very special solution for wooden houses, which have disadvantages that make them vulnerable to internal or external fires, such as grassland burning or forest fires; when a forest fire spreads, several houses and even entire inhabited areas will be lost.

[0263] In the face of forest fires that reduce forests, the death of trees caused by fire is one of the most destructive forces on Earth, which can undoubtedly be mitigated and contained by means of boundary panels utilizing the present invention. Containment panels with the composition of the present invention may well be a solution to prevent forest losses of up to 6 million hectares per year. This option may be a solution to restore the safeguarding of forests in ecosystems adapted to fires and prevent catastrophic events that alter soils, wildlife, and water quality.

[0264] The containment panels together with the composition of the present invention form fire containment barriers, which manage to contain and mitigate the fire for determined periods of time from 60 to 240 minutes, depending on their lengths and thicknesses of each rigid thin layer applied by the invention, to limit and restrict the vertical spread of fires, protecting real estate (buildings), forests, wooden houses, etc., the main objective being to safeguard human and wildlife life.

[0265] The examples and embodiments of the invention detailed above are merely illustrative and do not limit in any way the scope of the present invention.

Claims

CLAIMS 1. A fire-resistant, intumescent and water-repellent passive fire protection coating composition comprising: a) a dehydrating agent, b) a binding agent, c) an organic acid source, d) an organic carbon source, e) organic polymers, f) a fire-resistant agent, g) thermosetting elastomers, h) an organic adhesion agent, i) a resin agent, and j) a fiber agent, wherein the composition is applied in the form of at least a first layer which upon coming into contact with heat radiation by combustion does not form a thick carbonaceous layer which comes off and does not generate smoke.

2. The fireproof, intumescent, and water-repellent passive fire protection coating composition according to claim 1, wherein when the binding agent decomposes between 392 and 752 °F (200 and 400 °C) due to the increase in temperature, it provides a source of acids, whose dehydration reaction with the active aggregates of the binding agent acidifies and produces gases that form a gas source.

3. The fireproof, intumescent, and water-repellent passive fire protection coating composition according to claim 1, wherein the dehydrating agent extracts water from the binding agent and the organic carbon source, forming a glass film and microscopic flakes of quartz .

4. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein when the binding agent binds it is acidified generating silicic acid and the source of organic acid is added to reach a pH of 6.

63.

5. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the thermosetting elastomers limit the degradation of organic agents to reduce heat radiation, preventing the fire-resistant coating from becoming numb, in addition to eliminating smoke emission.

6. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the organic carbon source decomposes at a temperature of approximately 392 °F, producing a thermal process that involves melting and decomposition when the binding agent acidifies with the increase in temperature, an inversion reaction of the organic carbon source occurs up to its melting point, transforming into a thin layer with a carbonaceous structure.

7. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the organic polymers are transformed into a thin, rigid layer with a carbonaceous structure and Thermal insulation, where the gas source absorbs heat energy during the expansion and thermal boiling process, forming bubbles that are released and burst on the surface, thereby insulating the thermal conductivity of the thin carbon layer before stiffening.

8. The fireproof, intumescent and water-repellent coating composition for passive fire protection according to claim 1, wherein the fireproof agent inhibits combustion by affecting radical reactions, absorbs heat radiation by forming barriers to the passage of oxygen, interrupting the combustion cycle, reducing radiant energy levels from 2192 to 77 °F (1200 to 25 °C) in seconds, eliminating the progression of smoke and preventing the spread of fire, generating a layer of thermal insulation to combustion.

9. The fireproof, intumescent, and water-repellent passive fire protection coating composition according to claim 1, wherein the thermosetting elastomers do not melt when they reach a temperature of 1256 ° F, maintaining the structure of the multicellular carbonaceous thin layer in a solid state, difficult to remove, preventing the binding agent, the organic carbon source, the fireproofing agent, the organic adhesion agent, and the fiber agent from melting in the combustion zone in the intumescence process without degrading, wherein the fireproofing agent mitigates the cycle of combustion .

10. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the organic adhesive agent, when dehydrated by the dehydrating agent, forms a viscous vegetable substance that acts as an organic additive adhesive that provides a natural vitreous finish.

11. The fire-resistant, intumescent, and water-repellent passive fire protection coating composition according to claim 10, wherein the organic adhesion agent forms an adherent protective layer that reacts to the ignition source, wherein by applying two thin coating layers, the protective layer adheres between the multicellular carbonaceous layer and the inner rigid thin support layer, providing thermal protection, high adhesion properties that withstand extreme turbulent forces in a hydrocarbon fire.

12. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the matrix of the crystallization resin agent composition, which is composed of a mixture with calcium silicate, when reacting with a chemical base of amino alcohols and organic minerals are dispersed together with the binding agent containing quartz minerals, wherein the silicate becomes progressively more viscous, and where the removal of water absorbed by the dehydrating agent converts the silicate into a vitreous quartz film on the outside of each rigid thin layer of fireproof coating.

13. The fireproof, intumescent and water-repellent coating composition for passive fire protection according to claim 12, wherein additionally the dehydration and crystallization of the silicate is generated, converting it into microscopic quartz flakes, where together, the water-repellent agents are mixed with bituminous emulsions, waxes, fatty acids and butyl stearates, which allow lubrication, causing them to slide through the internal capillary system of the fireproof coating, which inside the substances are activated and form non-soluble invasive quartz crystals, which obstruct the entire microscopic capillary network, in any fissure up to 0.04 millimeters thick, preventing the filtration of water and humidity, drying the fireproof coating completely.

14. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the fiber agent is selected from inorganic fibers that provide more resistance to wear and environmental degradation with extreme weather changes, such as rain, sun, wind, UV rays, dust, humidity, water vapor, snow and prevents crystallization, which Protects the natural vitreous finish of each applied rigid thin layer, eliminating the possibility of instability in the face of high temperatures and fire containment.

15. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 14, wherein the synthetic inorganic polymeric fibers reduce cracks caused by contraction, prevent micro fissures, anti-leakage of liquids, prevent fractures in tension states of traction, bending, shear stress, torsion, provide maximum adhesion to the aggregates and resistance to impacts that are dispersed over a multidirectional network to reinforce each applied rigid thin layer of the fireproof, intumescent and water-repellent coating.

16. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the amount of the dehydrating agent is representative of 8-19% by weight based on the total weight of the composition, preferably 9-16% by weight, more preferably 10-17% by weight, and even more preferably 10-14% by weight.

17. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 16, wherein the amount of binding agent is representative between 46%- 61% by weight based on the total weight of the composition, preferably 46-59% by weight, more preferably 49-60% by weight, even more preferably 48-61% by weight and even more preferably 48-56% by weight.

18. The fireproof, intumescent, and water-repellent passive fire protection coating composition according to claim 1 or claim 17, wherein the amount of the organic acid source is representative of 0.4 to 2.9% based on the total weight of the fireproof coating composition, preferably 0.4-2.2% by weight, more preferably 0.4-2.7% by weight, even more preferably 0.6-2.9% by weight, and even more preferably 0.5-2.5% 19. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 18, wherein the amount of organic carbon source is representative of 0.2-2.58% based on the total weight of the fireproof coating composition, preferably 0.2-2.3% by weight, more preferably 0.4-2.5% by weight, even more preferably 0.3-2.1% by weight and even more preferably 0.3-1.8% by weight.

20. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 19, wherein the amount of organic polymers is representative between 0.2-2.9% based on the total weight of the composition, preferably 0.2-2.5% by weight, more preferably 0.3-2.4% by weight, even more preferably 0.3-2.9% by weight and even more preferably 0.2-2.1% by weight.

21. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 20, wherein the amount of the fire-resistant agent is representative of 1%-4.7% based on the total weight of the composition, preferably 1.1-3.8% by weight, more preferably 1-4.2% by weight, even more preferably 1.4-4% by weight and even more preferably 1.3-4.7% by weight.

22. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 21, wherein the amount of thermosetting elastomers is representative between 22 - 37% by weight, based on the total weight of the composition, preferably 24-33% by weight, more preferably 25-36% by weight, even more preferably 26 - 34% by weight.

23. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 22, wherein the amount of an organic adhesion agent is representative between 0.1-3.6% by weight based on the total weight of the composition, preferably 0.1-2.9% by weight, more preferably 0.2-3.1% by weight, even more preferably 0.3-3.4% by weight.

24. The fire-resistant, intumescent, and water-repellent passive fire protection coating composition according to claim 1 or claim 23, wherein the amount of a resin agent is representative of 0.2-3.7% by weight based on the total weight of the composition, preferably 0.2-2.6% by weight, more preferably 0.3-2.3% by weight, and even more preferably 0.4-2.9% by weight.

25. The fire-retardant, intumescent and water-repellent passive fire protection coating composition according to claim 1 or claim 24, wherein the amount of fiberizing agent is representatively between 0.2-4.1% by weight based on the total weight of the composition, preferably 0.3-3.5% by weight, more preferably 0.2-3.8% by weight and even more preferably 0.5%-3.3% by weight.

26. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the dehydrating agent is selected from a group of naturally occurring fibrous metamorphic minerals composed of double-chain silicates, complexes of iron, aluminum, sodium and magnesium.

27. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 26, wherein the dehydrating agent is sodium silicate fibers.

28. The fireproof, intumescent coating composition and passive fire protection water repellent according to claim 1, wherein the binding agent is selected from the group consisting of, but not restricted to the family of ortho-silicates, meta-silicates and pyro-silicates, wherein any ester containing a chemical group, such as tetramethyl ortho-silicate, can also be used.

29. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 28, wherein the preferred binding agent is liquid or powdered sodium silicate.

30. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 4, wherein the source of organic acid is citric acid.

31. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1 and claim 19, wherein the organic carbon source comprises carbohydrates.

32. The fireproof, intumescent and water-repellent coating composition for passive fire protection according to claim 1 and claim 20, wherein the organic polymers comprise organic polysaccharide polymers, wherein the organic polymers contribute to the transformation of the thin layer of carbonaceous structure and, at the end of the boiling process, to its rigidification.

33. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the source of organic carbon is sucrose.

34. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the fire-resistant agent is preferably perlite.

35. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the organic adhesive agent is Opuntia ficus mucilage.

36. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein the fiberizing agent is polypropylene.

37. A passive fireproof, intumescent and water-repellent coating system, comprising the composition of any of claims 1 to 36, which is applied as a replacement for cementitious mortar, where it is presented as a rough-looking paste-type fireproof mortar that protects and maintains the stability of buildings in the event of a fire, where its installation is very clean and simple by means of a brush, roller or electric airless equipment, providing maximum adherence, providing aesthetics and finish to the buildings. steel metal structures, walls, delaying, mitigating and minimizing the effects of flames.

38. A passive fire-resistant, intumescent, and water-repellent coating system, comprising the composition of any of claims 1 to 36, which can be supplied as a fire containment panel selected from the group consisting of gypsum board, cement board, metal panels, and panels made with fiberglass, wood, cardboard, and polystyrene foam facings.

39. A fire-resistant and water-repellent active fire protection composition comprising: a) a dehydrating agent, b) a binding agent, c) a source of organic acid, d) a source of organic carbon, e) organic polymers, f) a fire-resistant agent, g) thermosetting elastomers, h) an organic adhesion agent, i) a resin agent, and j) a fiber agent, wherein the composition is in the form of a powder, aerosol, or a silicone.

40. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of the dehydrating agent is representative of 8-19% by weight based on the total weight of said composition, preferably 9-16% by weight, more preferably 10-17% by weight, and even more preferably 10-14% by weight.

41. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of binding agent is representative of between 46%-61% by weight based on the total weight of said composition, preferably 46-59% by weight, more preferably 49-60% by weight, even more preferably 48-61% by weight and even more preferably 48-56% by weight.

42. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of the organic acid source is representative of 0.4 to 2.9% based on the total weight of said composition, preferably 0.4-2.2% by weight, more preferably 0.4-2.7% by weight, even more preferably 0.6-2.9% by weight, and even more preferably 0.5-2.5%.

43. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of organic carbon source is representative of 0.2-2.58% based on the total weight of said composition, preferably 0.2-2.3% by weight, more preferably 0.4-2.5% by weight, even more preferably 0.3-2.1% by weight and even more preferably 0.3-1.8% by weight.

44. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of organic polymers is representative between 0.2-2.9% based on the total weight of said composition, preferably 0.2-2.5% by weight, more preferably 0.3-2.4% by weight, even more preferably 0.3-2.9% by weight and even more preferably 0.2-2.1% by weight.

45. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of the fire-resistant agent is representative of 1%-4.7% based on the total weight of said composition, preferably 1.1-3.8% by weight, more preferably 1-4.2% by weight, even more preferably 1.4-4% by weight and even more preferably 1.3-4.7% by weight.

46. ​​The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of thermosetting elastomers is representative of between 22-37% by weight, based on the total weight of said composition, preferably 24-33% by weight, more preferably 25-36% by weight, even more preferably 26-34% by weight.

47. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of an organic adhesion agent is representative between 0.1-3.6% by weight based on the total weight of said composition, preferably 0.1-2.9% by weight, more preferably 0.2-3.1% by weight, even more preferably 0.3-3.4% by weight.

48. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of a resin agent is representative of between 0.2- 3.7% by weight based on the total weight of said composition, preferably 0.2-2.6% by weight, more preferably 0.3-2.3% by weight, and even more preferably 0.4-2.9% by weight.

49. The fire-resistant and water-repellent active fire protection composition of claim 39, wherein the amount of fiberizing agent is representatively between 0.2-4.1% by weight based on the total weight of said composition, preferably 0.3-3.5% by weight, more preferably 0.2-3.8% by weight and even more preferably 0.5%-3.3% by weight.

50. The fire-resistant and water-repellent composition for active fire protection of claims 39 to 49, wherein the powder may be present in fire extinguishers, in portable spheres and in containers suitable for extinguishing forest fires by aerial spraying.

51. A fire-resistant and water-repellent active fire protection system comprising the fire-resistant and water-repellent composition in liquid form of any of claims 39 to 49, which can be supplied as an aerosol, wherein an aerosol propellant and LPG gas are added to propel the substances contained in said aerosols, wherein the propellant is mixed with the liquid to be vaporized.

52. A fire-resistant and water-repellent active fire protection system comprising the fire-resistant and water-repellent composition in liquid form of any of the claims. 39 to 49, in the form of silicone in a gun can.

53. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein said first applied rigid thin layer of coating has a thickness of 0.2524 thousandths of an inch (0.006411 mm) that supports from 1652 to 2192 ° F (900 to 1200 ° C) of temperature, in determined times of 60 minutes for each thin and rigid layer, to protect the substrate, thus guaranteeing the stability of the steel or other construction materials and at least a second applied rigid thin layer of said coating, exposed to fire that does not allow heat transfer, keeping it below its critical yield temperature, of less than 932 ° F (500 ° C), even with high temperatures of the nature of 2012 ° F (1100 ° C).

54. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 53, wherein the application between one layer and another does not require the use of any element such as a support mesh applied between each layer for both cellulosic fires and hydrocarbon fires.

55. The fireproof, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein said composition provides a fireproof coating where its rigid thin layers have a vitreous quartz mineral finish that withstands, on the outside, extreme climatic changes such as sun, rain, wind, UV rays, dust, humidity, water vapor, snow, which does not crystallize, does not erode, does not come off and does not disintegrate due to its high adhesion properties.

56. The fire-resistant, intumescent and water-repellent passive fire protection coating composition according to claim 1, wherein said composition can be applied on any substrate without the need to apply a primer or base coat adhered to the substrate.