Intumescent GELS for rapid protection against fire and flame spread

Abstract

An intumescent gel composition for rapid fire protection comprising a transport phase and an activation phase to allow the composition to be fluidly conveyed through a hose and activated to form an intumescent gel upon application to the substrate, and methods for preparing and using the intumescent gel composition.

Description

[0001] INTUMESCENT GELS FOR RAPID PROTECTION AGAINST FIRE AND FLAME SPREAD

[0002] TECHNICAL FIELD OF THE INVENTION

[0003] The present invention relates to intumescent coatings and their applications. Specifically, the invention relates to an intumescent gel composition for rapidly imparting fire-retardant properties to a substrate and methods for using same.

[0004] BACKGROUND OF THE INVENTION

[0005] In the art of passive fire protection, intumescent coatings are known to be applied to substrates such as metals and wood. Intumescent materials can also be added to polymers and plastic nanocomposites which can be used to fire-proof putty and pipe. Intumescent materials swell when exposed to heat, resulting in a significant volume increase and a corresponding decrease in density. Various resin-based systems have been proposed for this purpose. Depending on the type, intumescent coatings may reduce flame spread rate, resist ignition, and / or insulate the coated surfaces.

[0006] Standard fire gels are another form of fire protection that provide effective barriers when hydrated, however they often suffer from high friction loss in delivery hoses or brittle “island formation” upon drying, which creates oxygen bypass gaps that allow substrates to ignite. Furthermore, many existing retardants rely on PFAS (Per- and Polyfluoroalkyl Substances) or corrosive organic neutralizers that present significant environmental risks in sensitive wildfire zones.

[0007] In recent years, the risk of fire and, in particular, rapid fire spread has been on the rise especially with increased urban densification and climate change. Climate change, forest mismanagement and increased construction in potential wildfire zones, has led to an increase in damage associated with wildfires. Specifically, the US government reports that 1 in 5 single family dwellings are subject to wildfire risk with a valuation of $8.4 trillion. Wildfire has also affected US, western Canada, Australia, Brazil, Chile, leading to substantial residential damage and loss of life.

[0008] The increase in urban densification has further led to the occurrence of rapid fire spread in densely populated areas which is particularly problematic in the case of lithium battery fires in both urban and suburban neighborhoods. Lithium fires are notoriously challenging to extinguish with existing technologies and fire departments attempt to mitigate the damage from battery fires on adjacent buildings, infrastructure and vehicles to reduce spread.

[0009] 90507254.1A need exists for intumescent coatings that can be rapidly deployed to impart immediate fire-retardant properties to substrates and structures that are in imminent danger of fire damage. A need exists for intumescent coatings that can reduce the risk from wildfires and prevent fire from transferring in dense residential areas.

[0010] This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

[0011] SUMMARY OF THE INVENTION

[0012] An object of the present invention is to provide an intumescent gel for rapid protection against fire and flame spread. In accordance with one aspect, there is provided an intumescent gel composition comprising a transport phase and an activation phase, wherein: (a) the transport phase comprises: a solvent, one or more intumescent additives, a gel-forming polymer, one or more charring agents, one or more barrier-forming agents; and (b) the activation phase comprises a pH modifier; wherein the activation phase is added to the transport phase immediately before application of the composition to a substrate, and wherein addition of the activation phase activates crosslinking with the transport phase to form the intumescent gel upon application to the substrate. In certain embodiments, the transport phase further comprises a binder.

[0013] In one embodiment, the transport phase and the activation phase synergistically react to form a stable barrier char upon exposure to fire. In a further embodiment, the intumescent gel is nontoxic, environmentally friendly, and does not emit toxic emissions.

[0014] In another aspect, the transport phase of the intumescent gel composition described herein has a viscosity of <100 cP to allow fluid flow through a hose without pressure drag, and wherein the activation phase has a gel viscosity to allow adhesion and coating to a substrate.

[0015] In one embodiment, the intumescent gel composition described herein has a wet state and a dry state, and wherein the intumescent gel composition provides at least 30 days of fire protection in the dry state. In a further embodiment, the intumescent gel composition provides up to 3 days of fire protection in the wet state. In another embodiment, the intumescent gel composition is rehydratable to extend the wet state of the composition and to provide up to 30 days of fire protection in the wet state.

[0016] 2

[0017] 90507254.1In another aspect, the intumescent gel composition described herein is washable from the substrate if not exposed to fire.

[0018] In another aspect, there is provided a method for protecting a substrate from fire, comprising: (a) conveying the transport phase of the composition described herein through a hose line to the substrate location; (b) adding the activation phase of the composition described herein to the transport phase at the outlet of the hose line and before application of the composition to the substrate; and (c) applying the intumescent gel composition to the substrate; wherein, addition of the activation phase activates crosslinking with the transport phase to form the intumescent gel upon application to the substrate.

[0019] In one embodiment, the method described herein allows the intumescent gel composition to be rapidly deployable to the substrate location under immediate threat of fire by spray application.

[0020] In another embodiment, the method described herein further comprises washing the intumescent gel composition off the substrate if not exposed to fire.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the accompanying drawings, which illustrate exemplary embodiments of the present invention:

[0023] FIG. 1 is a photo of the intumescent gel composition applied to various substrates, drywall, steel, glass, cardboard, and paper, to form a wet flame-retardant coating.

[0024] FIG. 2 are photos of glass samples coated with the intumescent gel composition before and after exposure to intense flame, and after washing.

[0025] FIG. 3 are photos of cardboard samples coated with the intumescent gel composition before and after exposure to intense flame, and after washing.

[0026] FIG. 4 shows glass coated with the intumescent gel composition, one without expandable graphite and one with expandable graphite.

[0027] FIG. 5 (A) is a photo of a glass sample coated with the intumescent gel composition in the dry state showing minimal island formation; (B) is a photo of a wood sample coated with the intumescent gel composition in the dry state showing minimal island formation; (C) is a photo of a cardboard sample coated with the intumescent gel composition in the dry state showing minimal island formation; (D) is a photo of a wood sample coated with a commercially available intumescent 3

[0028] 90507254.1coating in the dry state showing significant island formation; and (E) is a photo of a wood sample coated with a commercially available coating in the wet state showing significant island formation.

[0029] DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0030] Throughout the following description, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. The following description of examples of the invention is not intended to be exhaustive or to limit the invention to the precise form of any exemplary embodiment. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0031] Prior known intumescent coatings are typically used to provide a permanent coating on a substrate to impart long-term fire protection that is intended to extend beyond years and often over the lifetime of a specific structure. Such intumescent coatings are applied to building materials or structures in the form of a paint-like coating that functions as a protective fire-retardant layer. Such intumescent coatings are, therefore, applied far in advance of any anticipated danger.

[0032] According to embodiments, a composition is described that provides an intumescent coating that is rapidly deployable to impart immediate fire-retardant properties to a substrate. The intumescent composition of the present disclosure finds particular application in emergency situations such as in situations for controlling the spread of existing fires, as well as the risk of oncoming fires for example in densely populated areas, wildfires, and residential fires. In certain embodiments, the composition is particularly suited for emergency response, providing a rapidly deployable “wet shield” in the face of imminent fire risk that adheres to vertical and horizontal surfaces including wood, drywall, steel, and vegetation. According to embodiments, the wet shield provides temporary protection to the substrate and can be washed off when no longer needed thereby restoring the structure to its original state.

[0033] According to a first broad aspect, the intumescent coating is in a gel form that has a consistency and adhesiveness that is designed to coat flammable structures that include, for example, buildings, landscapes, outdoor furniture and flammable structures like awnings, and tents. In short, the intumescent composition can be readily applied to any substrate to provide immediate and rapid protection from fire. According to embodiments, the composition forms a coating that adheres to a substrate to create a uniform barrier.

[0034] 4

[0035] 90507254.1According to embodiments, the intumescent coating is in a gel form which allows for rapid and immediate fire suppression and protection. The gel form intumescent composition is rapidly deployable as a “wet shield” coating that can be readily and rapidly applied to a substrate using standard spray systems, for example, to create an effective barrier against fire damage. Accordingly, the flame-retardant composition is particularly suited for emergency fire hazard response. In contrast to paint-on coatings, the spray-on application of the intumescent gel composition allows the coating to be rapidly applied to a wider range of substrates and / or structures.

[0036] According to embodiments, the intumescent gel composition is formed through a two-phase system to allow for rapid deployment of the composition. The transport phase has a fluid viscosity such that the transport phase can be rapidly conveyed through a hose, for example, to the target site. At the hose outlet, or nozzle, the activation phase is added to the transport phase to activate crosslinking as the composition is applied to the substrate. In accordance with certain embodiments, the activation phase is a pH modifier added at the outlet nozzle or in situ through encapsulated pH modifiers. In such embodiments, the addition of the pH modifier (e.g., CaCCh) activates the gel-forming polymer (e.g., polyacrylic acid (carbomer)) to untangle to hydrate, and for further microscopic CO2 evolution which creates a micro-aerated mineral matrix that increases the “insulative loft” of the gel.

[0037] According to embodiments, binders such as vinyl acetate-ethylene (VAE) or other redispersible polymer powder (RPP) are added to the composition as plasticizers to prevent “island formation” in the gel during drying as well as to decrease the slumping of the wet gel when applied.

[0038] According to embodiments, the compositions can be readily applied as a spray using spray systems known in the art. In certain embodiments, the composition comprises gel-forming agents to control the viscosity for composition and uniform coverage. Both natural and synthetic gelforming agents can be used to provide thickening and stabilizing properties.

[0039] In the event of a fire, the coating rapidly forms a protective char layer, insulating the underlying substrate and preventing the spread of flames. This rapid response is crucial in emergency situations, providing valuable time for evacuation and firefighting efforts. According to embodiments, the intumescent composition is applied to a structure under imminent threat of fire to form an intumescent gel coating on the structure and to provide immediate fire protection. In certain embodiments, the fire is a wildfire and rapid application of the composition to structures at risk provides immediate fire protection. In other embodiments the composition is applied to a 5

[0040] 90507254.1structure adjacent to a structural fire to mitigate fire spread and to protect the structure from heat and fire damage. In further embodiments, the fire is an electric battery fire which endangers immediate infrastructure or vehicles.

[0041] In another broad aspect, the composition possesses a texture, robustness, and shape-retaining properties, to ensure a uniform coating on the substrate that does not drip off the substrate prior to or during fire exposure. The optimized viscosity and viscoelastic properties of the coating allow it to form a uniform, stable layer on various substrates, including wood, drywall, concrete, glass, textiles, outdoor furniture, and other building surfaces. This stability provides for the maintenance of the integrity of the coating under both normal conditions and high-temperature scenarios, to allow for consistent fire protection.

[0042] Upon exposure to heat or flame, the composition coated on the substrate undergoes a series of chemical and physical changes, leading to the formation of a protective char layer. This char layer acts as an insulating barrier, effectively reducing heat transfer and preventing the spread of fire. The intumescent action, combined with the charring effect and heat resistance, ensures that the coating provides robust fire protection.

[0043] In exemplary embodiments, the intumescent composition exhibits water retention properties. The composition comprises water absorbing polymers to create a gel that can hold water for days ensuring prolonged protection, even in extreme heat conditions. According to embodiments, the composition provides a wet shield that provides fire retardant protection to a substrate for up to 5 day, up to 4 days, up to 3 days, up to 2 days, or for at least 1 day. The extended water retention includes both hygroscopic materials like sodium polyacrylic acid which can be added to the gel and film-forming hydrophobic agents which prevent water loss of the coating. The composition according to certain embodiments further provides low temperature intumescent action. In such embodiments, the composition comprises intumescent additives which expand and form a stable char when exposed to heat. In further embodiments, the composition comprises barrier-forming agents, otherwise known as heat shield additives, to both reflect and absorb heat, enhancing the coating’s protective capacities. In other embodiments, the composition comprises binders and / or film-forming agents, to provide structural integrity to the gel coating, while allowing adhesion to substrates and the reduction of moisture loss.

[0044] According to a further broad aspect, the intumescent gel coatings continue to provide dry protection to the substrate when dry. In such embodiments, the composition continues to provide

[0045] 6

[0046] 90507254.1a dry protection to the substrate that remains effective even if flames do not strike the coated surface. According to certain embodiments, the dry protection has a duration of at least 30 days or longer. According to embodiments, the intumescent gel coating is washable. In particular, the composition can be washed off the substrate that it is applied to if not exposed to fire.

[0047] In another broad aspect, the composition is a water-based formulation thus allowing for easy cleaning and maintenance, making it suitable for environments where cleanliness and hygiene are important. In the absence of fire, the coating retains its flame-retardant properties, ensuring longterm protection and durability. In certain embodiments, the composition is eco-friendly and washable. The intumescent compositions comprise non-toxic, water-based materials. The gel composition is safe for the environment and can be conveniently washed away with water when no longer needed.

[0048] According to embodiments, an intumescent gel composition is described that, among other potential uses, may be used as an intumescent coating that is rapidly deployable to create a wet shield for immediate fire-protection to flammable structures and substrates. Upon drying, the intumescent gel composition forms a durable, fire-retardant barrier on the substrate, providing prolonged protection against potential fire hazards. In such embodiments, the dual-action functionality ensures both immediate response to fire threats and extended protection in scenarios of delayed or recurring fire risks.

[0049] Intumescent Gel Composition

[0050] According to embodiments, the intumescent gel composition comprises a transport phase and an activation phase.

[0051] / . Transport Phase

[0052] The transport phase has a fluid viscosity to allow fluid flow through a delivery device, such as a hose, without pressure drag. In certain embodiments, the fluid viscosity of the transport phase is less than 100 cP. In other embodiments, the fluid viscosity of the transport phase is less than 50 cP. In further embodiments, the fluid viscosity of the transport phase is less than 30 cP. In other embodiments, the fluid viscosity of the transport phase is between 30 and 50 CP.

[0053] According to embodiments, the transport phase comprises a solvent, one or more intumescent additives, a gel-forming polymer, one or more charring agents, and one or more barrier-forming agents.

[0054] 7

[0055] 90507254.1Solvent

[0056] The solvent acts as a medium to dissolve and disperse the other components of the composition. Known solvents can be used for this purpose. According to embodiments, water is commonly used due to its availability, cost-effectiveness, and non-toxic nature. In certain embodiments, the solvent content ranges from 50-90% by weight, ensuring the mixture remains fluid and easy to transport, deploy, and apply. In other embodiments, the composition comprises sufficient solvent to ensure a consistent mixture, uniform distribution, of components with a fluid viscosity needed for fluid flow.

[0057] Intumescent additives

[0058] Intumescent additives, otherwise known as fire-retardant active agents, actively contribute to the fire resistance of the coating. According to embodiments, the composition comprises one or more intumescent additives that include, without limitation, ammonium phosphate (AP), monoammonium phosphate, polyphosphate (APP), melamine, melamine phosphate (MP), melamine polyphosphate (MPP), aluminum hydroxide (ATH), magnesium hydroxide (MDH), calcium / magnesium carbonate, urea, dicyandiamide, or combinations thereof. It is contemplated that other known intumescent additives can be used. In such embodiments, these agents help to reduce the flammability of the substrate by promoting charring and releasing non-combustible gases. In certain embodiments, the intumescent additive I fire-retardant content is 1-40% by weight. In further embodiments, the one or more intumescent additives is a solution of the one or more intumescent additives dissolved in water to ensure uniform distribution of the one or more intumescent additives in the composition.

[0059] Gel Forming Polymers

[0060] According to embodiments, the composition comprises a gel forming polymer comprising one or more synthetic polyacrylic acid or acrylic resin, or natural cellulosic polymers. Non-limiting examples of gel-forming compounds include polyacrylic acid (PAA), carbomer, cellulose nanocrystals (CNC), carboxymethyl cellulose (CMC), various plant gums (such as guar gum, Arabic gum, tragacanth gum, karaya gum, cassia gum, locust bean gum, fenugreek gum, tamarind gum, and psyllium husks), agarose, alginate, carrageenan, chitosan, collagen, gelatin, hyaluronic acid, pectin, pullulan, starch, and xanthan gum. In such embodiments, the gel forming polymer creates a hydration barrier between the flame / heat and the underlying substrate, helping to prevent the spread of fire. In certain embodiments, the gel content is 1-10% by weight, providing sufficient barrier properties without compromising the coating's overall performance.

[0061] 8

[0062] 90507254.1Charring Agents

[0063] Charring agents promote the formation of a protective char layer when exposed to fire. This char layer acts as an insulating barrier, slowing down heat transfer and protecting the underlying substrate. In certain embodiments, the charring agent content ranges from 1-20% by weight. According to embodiments, the composition comprises charring agents that include pentaerythritol (PER), dipentaerythritol, dipentaerythritol (Di-PER), tripentaerythritol (Tri-PER), starch, sucrose, sorbitol, tannic acid, glucose, polyols (e.g., glycerol), or combinations thereof.

[0064] Barrier-forming Agents

[0065] Barrier-forming agents enhance the barrier properties of the coating by forming a physical barrier against heat and flames. Non-limiting examples of such agents include members of the graphene family (graphene, graphene nanosheets, graphene oxide, graphene nanocomposite (polyaniline, metal oxides decorated graphene), graphene guantum dot), expandable graphite, graphitic carbon nitride (g-C3N4), and various mineral fillers, nanomaterials and nanoclays (such as Organoclay, Montmorillonite, talc, calcium carbonate, lamellar kaolin, mica, barytes (barium sulfate), silica, glass microbeads, alumina, pumice, bentonite and zeolite) or combinations thereof. In certain embodiments, the barrier-forming agent is a nanomaterial or mineral filler modified with thermally stable components sandwiched with intumescent active agents such as melamine, nanoclay, expandable graphite, graphene, or combinations thereof. In certain embodiments, the barrierforming agent content is 1-10% by weight.

[0066] According to certain embodiments, expandable graphite is the preferred barrier-forming agent and / or intumescent additive for its multi-functional properties and environmental-friendliness. In such embodiments, the expandable graphite is dual-sized or multi-sized flakes that allow for the larger flakes (i.e., 80 mesh) to create an extended char while smaller (i.e., 200 mesh) flakes fill the interstitial voids between the larger expanded flakes to create a smoke and oxygen-tight seal and greater stability.

[0067] Binders

[0068] In certain embodiments, the transport phase may further comprise a binder. Binders, otherwise known as film forming agents, improve the adhesion and cohesion of the coating. They help the gel adhere to the substrate and maintain its integrity under fire exposure. According to embodiments, the composition comprises binders including without limitation, polyvinyl alcohol

[0069] 9

[0070] 90507254.1(PVA), polyacrylic, and polyvinyl acetate (PVAc), vinyl acetate-ethylene (VAE) redispersible polymer powder, or combinations thereof. In certain embodiments, the binder further comprises one or more high molecular weight biopolymers. In certain embodiments, the binder content ranges from 1-10% by weight, ensuring a strong and durable coating.

[0071] Adhesion Promoters

[0072] According to embodiments the transport phase may further comprise adhesion promoters to enhance or improve the adhesion of the coating to the substrate, ensuring it remains in place during fire exposure. Non-limiting examples include silane coupling agents and other adhesionpromoting chemicals. In certain embodiments, the adhesion promoter content is 0.1-2% by weight, used as needed to enhance the coating's performance.

[0073] Plasticizers

[0074] According to embodiments the transport phase may further comprise plasticizers to maintain film flexibility during drying and to prevent “island formation” and sagging of the gel on application to the substrate. Non-limiting examples include nanoclays, vinyl acetate ethylene (VAE), and redispersible polymer powder (RPP).

[0075] / / . Activation Phase

[0076] The activation phase is added to the transport phase immediately before application of the composition to a substrate to activate crosslinking with the transport phase to form the intumescent gel upon application to the substrate. According to embodiments, the activation phase comprises a pH modifier or physical crosslinker. Non-limiting examples of the pH modifier include metal hydroxides such as calcium hydroxide Ca(OH)2 or aluminum hydroxide AI(OH)a, sodium carbonate, calcium carbonate, sodium bicarbonate, aminomethyl propanol (AMP), or combinations thereof. In certain embodiments, the composition comprises 0.1-2% by weight of the pH modifier.

[0077] According to certain embodiments, a pH modifier can further be added to the final intumescent gel to modify the dimensional stability of the gel once it is applied on surfaces. For example, calcium chloride (CaCl2) can be added after the application of the gel to create ionic crosslinking to facilitate removal of the gel as clumps to minimize the dissolving of the gel when washing. In this way, all materials can be disposed of and kept from riparian zones.

[0078] 10

[0079] 90507254.1Preparation of Intumescent Gel

[0080] Without limiting the generality of the following, the intumescent gel compositions described herein can be prepared using standard procedures known in the art. According to embodiments, the intumescent gel compositions are prepared in accordance with the general preparation process that comprises the following steps:

[0081] / . Preparation of Transport Phase

[0082] The transport phase is prepared by mixing each of the components into the solvent to a uniform consistency and fluid viscosity.

[0083] • Dissolution of Binders and Film-forming Agents in the Solvent: Binders, such as polyvinyl alcohol (PVA), and film-forming agents are added to the mixture. These components provide structural integrity to the coating, ensuring it adheres well to various substrates and forms a continuous, protective film.

[0084] • Incorporation of Barrier-forming Agents: Barrier-forming agents, such as graphene, graphene oxide, expandable graphite, and bentonite are incorporated into the mixture. These materials enhance the barrier properties of the coating by forming a physical barrier against heat and flames.

[0085] • Addition of Intumescent Additives: Intumescent additives including melamine, melamine phosphate (MP), melamine polyphosphate (MPP), ammonium phosphate (AP), ammonium polyphosphate (APP) and aluminum hydroxide (ATH), are added to the mixture. These agents reduce the flammability of the substrate by promoting intumescence upon exposure to heat. It decomposes to release phosphoric acid, which catalyzes the charring process and forms a protective barrier.

[0086] • Incorporation of Charring Agent: The charring agent, such as pentaerythritol, is incorporated into the mixture. This agent aids in the formation of a stable char layer, acting as a carbon source and enhancing the char formation.

[0087] • Addition of gel-forming polymer: This step ensures that the gel-forming agent is fully integrated into the solvent, providing the necessary viscosity for the coating. Gel forming polymers, such as polyacrylic acid (PAA), create a hydration barrier and contribute to the 11

[0088] 90507254.1overall structure of the gel. The use of water as a solvent is advantageous due to its nontoxic, non-flammable, and readily available nature, making the formulation process safer and more environmentally friendly.

[0089] • Optional Addition of Adhesion Promoters: If needed, adhesion promoters are added to the mixture. These compounds improve the adhesion of the coating to the substrate, ensuring it remains in place during fire exposure.

[0090] / / . Preparation of Activation Phase

[0091] The activation phase is separately prepared as a mixture of the pH modifier with a solvent to form a uniform consistency. In embodiments requiring rapid deployment, e.g., spray application to a substrate, the activation phase is added to the transport phase immediately before application. In other embodiments, the activation phase may be added to the transport phase by mixing into the activation phase in advance. Addition of the activation phase results in interaction with the transport phase gel matrix to enhance its dimensional stability and mechanical strength once applied to a surface. This addition ensures the gel maintains its structural integrity under environmental stresses and during fire exposure.

[0092] Uses

[0093] The intumescent gel compositions described herein can be used to provide a fire-protective coating on a variety of substrates where such intumescent coatings are needed. The intumescent coatings expand into a thick insulating char when exposed to high temperatures. This swelling action slows heat transfer, protecting underlying materials from structural failure. Their versatility and thin-film application make the intumescent composition valuable across numerous industries, structures, and building types. Depending on the circumstances and substrate to be coated, the intumescent gel composition is amenable to a variety of application methods. For example, the intumescent gel composition can be painted onto a substrate to form the coating. Alternatively, and advantageously, the intumescent gel composition can be rapidly applied, e.g., sprayed, onto a substrate to form the coating.

[0094] According to embodiments, the intumescent gel composition described herein comprises a transport phase for fluid conveyance of the composition through a rapid delivery device, such as a hose, and an activation phase for functional adhesion of the coating onto the substrate. In this 12

[0095] 90507254.1way, the intumescent gel composition is rapidly deployable to the substrate location under immediate threat of fire by spray application. In certain embodiments, the immediate threat is a wildfire. In other embodiments, the substrate is a structure adjacent to a structural fire.

[0096] In one exemplary embodiment, the transport phase is pumped through a hose line to the substrate location; the activation phase is added to the transport phase at the outlet of the hose line and before application of the composition to the substrate; and the intumescent gel composition is then applied / sprayed onto the substrate. In such embodiments, the addition of the activation phase activates crosslinking with the transport phase to form the intumescent gel upon application to the substrate.

[0097] According to embodiments, the intumescent gel composition has a wet state and a dry state. In the wet state, the intumescent gel composition provides 3-5 days of fire protection. According to other embodiments, the intumescent gel composition provides up to 3 days of fire protection. In further embodiments, the fire protection of the intumescent gel coating in the wet state can be extended by rehydrating the coating. In such embodiments, the intumescent gel composition is rehydratable to extend the wet state of the composition to up to 10 days, up to 20 days, up to 30 days or up to 50 days. In the dry state, according to embodiments, the intumescent gel composition provides at least 10 days, at least 20 days, at least 30 days, at least 35 days, at least 40 days, or at least 50 days of fire protection. In further embodiments, the intumescent gel composition can adhere to a non-porous glass substrate to form a coating that prevents shattering when exposed to flames of approximately 700 °C.

[0098] Once the fire risk has passed, it will typically be desired to restore the substrate to its original state. According to embodiments, the intumescent gel composition is washable from the substrate if not exposed to fire. In such embodiments, the intumescent gel composition may be washable from the substrate using coagulants that include, without limitation, one or more of CaCl2, AI(OH)3, Ca(OH)2.

[0099] To gain a better understanding of the invention described herein, the following examples are set forth. It will be understood that these examples are intended to describe illustrative embodiments of the invention and are not intended to limit the scope of the invention in any way.

[0100] 13

[0101] 90507254.1EXAMPLES

[0102] Example 1: Exemplary Formulation

[0103] This example illustrates the step-by-step process for preparing and applying a gel intumescent composition designed to provide an effective fire protection coating for flammable substrates. The process involves the precise mixing of various components to form a stable gel that can be easily applied and provides a protective barrier upon exposure to heat or flame.

[0104] 1. Mixing Solvent and Binder: In a mixing vessel, 86% by weight of water is combined with 2% by weight of polyvinyl alcohol (PVA). The mixture is stirred until the PVA is fully dissolved.

[0105] 2. Incorporation of Nanoclay: Next, 2% by weight of bentonite is added to the solution. The mixture is stirred thoroughly for 5 minutes to ensure uniform dispersion of the nanoclay.

[0106] 3. Addition of Intumescent Additive: 5% by weight of ammonium polyphosphate (APP) is then added to the mixture. The solution is mixed for an additional 5 minutes to ensure the APP is well integrated.

[0107] 4. Incorporation of Charring Agent: Following this, 5% by weight of pentaerythritol (PER) is added to the mixture. The solution is stirred for another 5 minutes to ensure even distribution.

[0108] 5. Addition of Gel Forming Polymer: 2% by weight of polyacrylic acid (PAA) is added to the mixture. The solution is mixed for 5 minutes until a gel is formed.

[0109] 6. pH Adjustment: Finally, the pH of the mixture is adjusted to 9 to stabilize the gel.

[0110] The gel is sufficiently stable to be applied to various surfaces using methods such as brushing, rolling, or spraying, on a variety of substrate types and application requirements.

[0111] Example 2: Exemplary Formulation

[0112] This example illustrates an alternative method for preparing and applying a gel intumescent composition, highlighting the versatility of the formulation process and the effectiveness of the resulting fire protection coating.

[0113] Formation of the Additive:

[0114] 1. Dissolving the Binder in the Solvent: In a mixing vessel, 86% by weight of water is combined with 2% by weight of polyvinyl alcohol (PVA). The mixture is stirred until the PVA is fully 14

[0115] 90507254.1dissolved.

[0116] 2. Incorporation of Nanoclay: Next, 2% by weight of nanoclay is added to the solution. The mixture is stirred thoroughly for 5 minutes to ensure uniform dispersion of the nanoclay.

[0117] 3. Addition of Barrier-forming Agent: 2% by weight of expandable graphite (EG) is added to the mixture. The solution is mixed for 5 minutes to ensure uniform dispersion.

[0118] 4. Addition of Intumescent Additive: 4% by weight of ammonium polyphosphate (APP) is then added to the mixture. The solution is mixed for an additional 5 minutes to ensure the APP is well integrated.

[0119] 5. Incorporation of Charring Agent: Following this, 3% by weight of pentaerythritol (PER) is added to the mixture. The solution is stirred for another 5 minutes to ensure even distribution.

[0120] 6. Addition of Gel Forming Polymer: 2% by weight of polyacrylic acid (PAA) is added to the mixture. The solution is mixed for 5 minutes until a gel is formed.

[0121] 7. pH Adjustment: Finally, the pH of the mixture is adjusted to 9 to stabilize the gel.

[0122] The gel is sufficiently stable to be applied to various surfaces using methods such as brushing, rolling, or spraying, depending on the substrate type and application requirements.

[0123] Example 3: Exemplary Formulation

[0124] This example illustrates an alternative method for preparing and applying a gel intumescent composition, ensuring a synergistic effect that enhances the gel's fire protection performance when exposed to heat or flames.

[0125] 1. Incorporation of bentonite: In a mixing vessel, 86% by weight of water is combined with 2% by weight of bentonite. The mixture is stirred thoroughly for 5 minutes to ensure uniform dispersion of the nanoclay particles.

[0126] 2. Addition of Barrier-Forming Agent: 2% by weight of expandable graphite (EG) is added to the nanoclay mixture. The solution is mixed for an additional 10 minutes to ensure even distribution of the expandable graphite and its interaction with the bentonite layers.

[0127] 3. Addition of Intumescent Additives: 4% by weight of ammonium polyphosphate (APP) and 3% by weight of pentaerythritol (PER) are added sequentially to the mixture. The solution is stirred continuously for 30 minutes, allowing the intumescent additives to penetrate through the layered structures of the bentonite and expandable graphite (EG). This process improves the interaction between the additives and the barrier-forming agents, enhancing

[0128] 15

[0129] 90507254.1the intumescent performance of the gel under heat or flame exposure.

[0130] 4. Dissolution of Binder in the Solvent: Separately, 2% by weight of polyvinyl alcohol (PVA) is dissolved in the solvent by stirring until fully dissolved. The PVA solution is then added to the prepared mixture. The mixture is stirred for 5 minutes to ensure proper integration of the binder.

[0131] 5. Addition of Gel-Forming Polymer: 2% by weight of polyacrylic acid (PAA) is added to the combined solution. The mixture is stirred for 5 minutes, forming a gel with the desired viscosity and structure.

[0132] 6. pH Adjustment: The pH of the mixture is adjusted to 9 using a suitable base to stabilize the gel composition.

[0133] 7. Application: The prepared gel is applied to various surfaces using methods such as brushing, rolling, or spraying, depending on the substrate type and application requirements. The gel adheres effectively to the substrate, forming a uniform and protective intumescent coating.

[0134] Example 4: Exemplary Formulation

[0135] This example illustrates a method for both preparing and spraying the intumescent gel composition ensuring a synergistic effect from a delayed hydrated layer and extend performance while dry.

[0136] 1. A granulated combination of dry powders, or a blended formula of the following dry powders are added into a tank that is being agitated through a fire pump’s recirculation at the following concentration.

[0137] a. Self-wetting carbomer at 0.6%

[0138] b. Ammonium Polyphosphate 1.0%

[0139] c. Monoammonium Phosphate 0.2%

[0140] d. Pentaerythritol or Di Pentaerythritol (PER or Di-PER) 2%

[0141] e. 80 mesh expandable graphite 2.5%

[0142] f. 200 mesh expandable graphite 0.5%

[0143] g. Propylene glycol 2%

[0144] h. Alcohol Ethoxylate 1%

[0145] i. Polyglycol 3 oleate 1%

[0146] j. Bentonite 1%

[0147] k. Sodium Metasilicate 0.5%

[0148] l. Fumed silica 0.2%

[0149] 16

[0150] 90507254.12. The above formula is mixed in a tank for approx. 3-5 minutes until uniform consistency is achieved. Ideally, the input and output of the tank is located and designed to induce a vortex into the tank so that the powder is introduced into the vortex to improve mixing. 3. The gel has a viscosity < 100cP.

[0151] 4. The gel is sprayed with a high pressure water pump that can deliver a minimum of 65 psi at the nozzle. The high pressure allows for the gel to be sprayed at sufficient distance to cover a wide area.

[0152] 5. A nozzle is chosen to deliver at a rate of 30 gpm to cover structures rapidly, while also minimizing the amount of gel used.

[0153] 6. The pH adjustment is added through an inlet into the main delivery hose just before the nozzle to prevent clogging and to prevent gelation from occurring in the hose.

[0154] The gel is sufficiently stable to adhere to the substrate and is sufficiently fluid to be delivered through a hose and sprayed onto the substrate.

[0155] Example 5: Applicability to Range of Substrates

[0156] This example illustrates the rapid application of the intumescent composition on various substrates to form a wet shield, flame retardant coating. FIG. 1 demonstrates the application of the intumescent composition on various substrates, including drywall, steel, glass, cardboard, and paper. The intumescent gel was prepared using the method outlined in Example 2, ensuring a uniform and stable formulation. The prepared gel was then applied to each substrate using methods such as brushing, rolling, or spraying to achieve a consistent coating thickness. Once applied, the coated surfaces were examined for adhesion, cohesion, and stability properties, focusing on their performance on both rough and smooth vertical surfaces.

[0157] The results indicate that the intumescent composition displayed excellent adhesion across all tested substrates, including porous and wettable surfaces like drywall, cardboard, and paper and non-porous and slippery surfaces like steel and glass. The coating also exhibited outstanding cohesion and stability, with no dripping or sagging observed, even on vertical or slippery surfaces such as glass. These findings demonstrate the feasibility of the intumescent composition for fire protection applications, as it forms a stable, uniform layer with strong adhesion and high resistance to displacement. This versatility highlights its potential to protect a wide range of materials and surfaces from fire hazards effectively.

[0158] 17

[0159] 90507254.1Example 6: Intumescent Performance on Glass Substrate

[0160] This example illustrates the effectiveness of the intumescent composition to protect the coated substrate from damage by exposure to intense flame. As well, the easy clean-up of the substrate after exposure to the flame is demonstrated. FIG. 2 illustrates the performance of the intumescent composition that was applied to a glass substrate before, during, and after exposure to intense flame. The intumescent gel was prepared and uniformly applied to the glass surface. The coated glass was then subjected to a high-temperature flame (around 800 °C) to evaluate the protective properties of the composition. Following the exposure, the substrate was allowed to cool, and the coating was wiped off to assess its removability and the condition of the underlying glass.

[0161] The intumescent composition provided exceptional protection to the glass substrate during exposure to intense flame, effectively preventing heat-induced damage such as cracking or shattering. This demonstrates the potential of the coating to safeguard sensitive glass surfaces, such as building windows, which are particularly vulnerable to extreme heat. Furthermore, the coating could be easily washed off after exposure without significant effort, leaving the glass surface clean and intact. These findings highlight the practical utility of the intumescent composition in protecting glass surfaces from fire hazards while maintaining their long-term usability.

[0162] Example 7: Intumescent Performance on Carboard Substrate

[0163] This example illustrates the effectiveness of the intumescent composition to protect a coated cardboard substrate from damage by exposure to intense flame. FIG. 3 illustrates the performance of the intumescent composition applied to a cardboard substrate before, during, and after exposure to high-temperature flames of approximately 800°C. The intumescent gel was prepared and uniformly applied to the cardboard surface using spray coating. The spray coated cardboard was then exposed to direct flames under controlled conditions to evaluate the thermal and fire-protective behavior of the coating. The observations during and after exposure were documented to assess the formation of a protective barrier and the substrate's condition.

[0164] The results confirm the effectiveness of the intumescent coating in protecting flammable substrates such as cardboard from high-temperature flames. When exposed to heat, the intumescent composition undergoes a reaction facilitated by its charring agent, causing it to expand and form a stable char layer. This char layer acts as a thermal barrier, shielding the substrate from direct

[0165] 18

[0166] 90507254.1exposure to flames and preventing combustion. The findings demonstrate the coating's ability to transform and create a robust protective layer, making it an effective fire-retardant solution for vulnerable surfaces.

[0167] Example 8: Enhanced Intumescent Performance on Glass Substrate

[0168] This example compares the effect of the addition of a barrier-forming additive (i.e., expandable graphite) on the effectiveness of the intumescent coating to protect a glass substrate from damage by exposure to intense flame. FIG. 4 depicts the performance of two intumescent compositions applied to glass substrates — one containing expandable graphite and the other without it. Both compositions were prepared using the standard method and applied to vertical glass surfaces using a brush to ensure consistent coating thickness. Observations were recorded to evaluate the adhesion, stability, and performance of both formulations on smooth, non-porous glass substrates.

[0169] Both intumescent compositions demonstrated excellent adhesion to the glass surface, forming a uniform layer that remained stable on the vertical substrate without dripping or sagging. Additionally, the composition containing expandable graphite exhibited superior performance by providing enhanced intumescent protection when exposed to flames. The expandable graphite facilitated the formation of a robust char layer, effectively shielding the glass substrate from intense heat and flame damage. This result highlights the significant role of expandable graphite in optimizing fire protection for smooth and sensitive surfaces like glass.

[0170] Example 9: Controlled Viscosity of the Gel for Rapid Deployment (Sprayability)

[0171] The rapid deployment, or sprayability, of the intumescent gel composition is further demonstrated with exemplary formulation prepared as follows:

[0172] Twenty-seven kilograms of a granulated combination of a dry powder formulation is added to a 400 liter water tank that is attached to a fire pump truck. The dry formulation is comprised of the following ingredients with a corresponding final % wt. in the mixture in the water tank.

[0173] a. Self-wetting carbomer at 0.6%

[0174] b. Ammonium Polyphosphate 1.0%

[0175] c. Monoammonium Phosphate 0.2%

[0176] d. Pentaerythritol or DiPentaerythritol (PER or Di-PER) 2%

[0177] 19

[0178] 90507254.1e. 80 mesh expandable graphite 1.5%

[0179] f. 200 mesh expandable graphite 0.5%

[0180] g. Bentonite 1%

[0181] The dry powder is added to the tank with the pump recirculating the mixture. The formulation is recirculated for approx. 3-5 minutes until uniform consistency is achieved. The input and the output of the tank is designed so that the recirculation induces a vortex to increase the speed of the dispersion. A Zahn cup #3 was used to identify the viscosity of the formulation by measuring the time it takes for the cup to empty. The cup was lowered in the mixture and measured repeatedly. The time for the cup emptying was 9.8s which corresponds to a viscosity <30cP.

[0182] After the mixture was uniform, the fire pump manifold was switched to spray and the mixture was pumped through a 1.5” fire hose with a traditional fog / stream adjustable nozzle at approximately 65 psi. The profile of the fog / stream was similar to when only water was used.

[0183] 1 kg of sodium carbonate was placed into 4 liters of water and mixed thoroughly to be used as the pH modifier which is injected into the stream. The injection is performed by a 12V pump that pumped the sodium carbonate mixture through a garden hose attached to a water thief “t junction” just before the fire nozzle. Sodium carbonate was selected due to its environmental profile and general safety for end users. The injection rate of the sodium carbonate solution into the spray formulation was at a ratio of 1:100.

[0184] Immediately upon having sodium carbonate introduced into the spray formulation there is little change in the spray pattern. However, when the total formulation with the sodium carbonate pH modifier was sprayed onto a building 10' away, the gel was firming and grew to a semi-solid coating that was over 1cm thick. The actual viscosity of the gel was not measured as it was too thick for traditional Zahn cup measurements, but the formulation was thicker than chocolate syrup ~ 15,000 cP and was likely > 30,000cP.

[0185] This demonstration indicates that the formulation changes viscosity to a thick gel within a few seconds after the pH modifier is added to the formulation, otherwise the gel would have washed down the building instead of producing a gel.

[0186] 20

[0187] 90507254.1Example 10: Intumescent Performance

[0188] The intumescent performance of the intumescent gel composition was demonstrated in the wet state and the dry state. The following formulation was mixed with water using a silverson mixer at low speed for 30 minutes. The components and the %wt of the components in the final mixture is the following:

[0189] a. Carbomer 940 at 1.0%

[0190] b. Ammonium Polyphosphate 1.0%

[0191] c. Monoammonium Phosphate 0.5%

[0192] d. Pentaerythritol (PER) 2%

[0193] e. 80 mesh expandable graphite 1.5%

[0194] f. 200 mesh expandable graphite 0.5%

[0195] g. Bentonite 1%

[0196] h. Urea 1%

[0197] To this mixture 0.1% of NaHCO3was added and thoroughly mixed creating a gel with an estimated viscosity >30,000 cP. The mixture became a firm gel in less than 5 minutes.

[0198] The wet gel was placed on a wooden plywood sample that was 8cmx8cm. The sample was placed in a holder and a bernzomatic propane torch was lit. The torch was placed 1.5” from the coated wooden sample. The sample was exposed to the torch for 10 min and then the torch was extinguished. The coating demonstrated some charring or discoloration where the flame interacted with the coating. The coating was washed from the board and no physical damage was observed on the wooden surface.

[0199] The gel was also applied to! ” OSB at a thickness of 3mm and 6mm and left to dry for five days. The samples were sent to a third-party lab for ASTM E84 testing and was tested 31 days after the coating was applied. The dried gel achieved Class A fire rating, the highest, with the Flame Spread Index (“FSI”) of 25 for the low thickness (3mm) and the high (6mm) measured with an FSI of 5.

[0200] Example 11: Consistent Coating

[0201] The consistency and uniformity of the above coating applied to, and allowed to dry, on glass, wood and carboard was observed. In particular, the coating was observed for the occurrence of “island

[0202] 21

[0203] 90507254.1formation” upon drying, i.e., cracking, which creates oxygen bypass gaps that allow substrates to ignite.

[0204] As shown in FIGS. 5(A), (B), and (C), the coating showed minimal island formation on each of the tested substrates in comparison to a commercially available coating shown applied to a wood sample in the dry and wet state (D).

[0205] Example 12: Ease of Removal

[0206] The easy and complete removal of the coating was demonstrated. The formulation from the fire test example above was exposed to a propane flame for 2.5 min under the direction of a fire marshall 20 minutes after the coating was applied. The coated structure appeared to have minimal damage after the fire test. A fire hose delivering 75psi water was used to spray the structure and the gel coating was removed in seconds with the water.

[0207] The same formulation from the fire test example was left on the opposite side of the structure to dry in the sun for eight days on a 10ft x 8ft wall. A fire hose delivering water through a nozzle at 75psi was sprayed onto the building to remove the coating. Over 200 gallons of water was used to remove the coating and removal required over 1 hour.

[0208] Lab testing confirmed the challenge of the above formulation when dried on wooden samples. The same formulation was tested in a lab and used to coat 8cm x 8cm plywood samples. After the coating was dried in an oven overnight, the samples were rinsed for 30s in cold water. The damp samples were left for 10 minutes and then were rinsed in tap water with an accompanying light scrub from a j-cloth. The time for all the coating was measured when cold water was used and hot water from the tap was used. Samples cleaned under cold water required 3 min 17s of rinsing and light scrubbing to remove all the coating. Samples that were cleaned with hot water rinsing required on average 1min 42s.

[0209] Additives to improve the washability of the formula were tested including in the full formulation including Propylene Glycol (PG), Polyglyceryl-4 Oleate (PGO) and Glycerine (G). Table 1 are the results of a washability test where samples with coating oven dried on them were soaked in 30s of cold water, left for 15 minutes and then rinsed under a tap using cold water. After 20s of rinsing, a light scrubbing until the coating was gone. When 4% PG was added to the mix, 20% of the coating was removed during wetting and the remainder was removed in 5.6s without any scrubbing. The same performance was achieved with 0.5PG and 2% PGO. When 2% PG and

[0210] 22

[0211] 90507254.12% Glycerin were used as additives, the gel produced was stickier and adhered to vertical surfaces better than with the other additives or no cleaning additives. The cleaning was slightly impacted by this formulation as cleaning required 12-14 second.

[0212] The disclosures of all patents, patent applications, publications and database entries referenced in this specification are hereby specifically incorporated by reference in their entirety to the same extent as if each such individual patent, patent application, publication and database entry were specifically and individually indicated to be incorporated by reference.

[0213] Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention. All such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

[0214] 23

[0215] 90507254.1Table 1: Washability Test

[0216]

[0217] 1 PG-0.5% 10.8 s / 55% gel / no drip '10% 25 s - light scrub 2 PG -4% 85% gel / no drip <10% 5-6 s - no scrub

[0218] 3 PG-3 + PGO 1% 85% gel / no drip < PG 0.5% 5 s - no scrub

[0219] 4 PG05+PGO 2% 85% gel! no drip < PG 0.5% 5-6 s - no scrub

[0220] 5 PG 2 +PGO 2 % 85% gel! no drip < PG 0.5% 5 s - no scrub

[0221] 6 PG 2 + Glycerin 2% 85% gel / no drip / sticky gel '10% 12-14 s no scrub

[0222] 7 PG 05 + Glycerin 1% 85% gel / no drip / sticky -10% 26-28 s light scrub / large flakes

[0223] 8 PG 05 + Glycerin 2% 85% gel / no drip / sticky -10% 24-25 s light scrub / large flakes

Claims

CLAIMS1. An intumescent gel composition comprising a transport phase and an activation phase, wherein:a. the transport phase comprises:a solvent,one or more intumescent additives,a gel-forming polymer,one or more charring agents,one or more barrier- forming agents; andb. the activation phase comprises a pH modifier;wherein the activation phase is added to the transport phase immediately before application of the composition to a substrate, and wherein addition of the activation phase activates crosslinking with the transport phase to form the intumescent gel upon application to the substrate.

2. The composition of claim 1, wherein the transport phase further comprises a binder.

3. The composition of claim 1 or 2, wherein the one or more intumescent additives is ammonium phosphate (AP), monoammonium phosphate, ammonium polyphosphate (APP), melamine, melamine phosphate (MP), melamine polyphosphate (MPP), aluminum hydroxide (ATH), magnesium Hydroxide (MDH), calcium / magnesium carbonate, urea, dicyandiamide, or combinations thereof.

4. The composition of claim 3, wherein the one or more intumescent additives is a solution of the one or more intumescent additives dissolved in water to ensure uniform distribution of the one or more intumescent additives in the composition.

5. The composition of any one of claims 1-4, wherein the composition comprises 1-40% by weight of the one or more intumescent additives.

6. The composition of any one of claims 1-5, wherein the gel-forming polymer is one or more synthetic polyacrylic acid or acrylic resin, or natural cellulosic polymers.

7. The composition of any one of claims 1-6, wherein the composition comprises 1-10% byweight of the gel-forming polymer.

8. The composition of any one of claims 1-7, wherein the binder is polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), or vinyl acetate-ethylene (VAE) redispersible polymer powder, or combinations thereof.

9. The composition of claim 8, wherein the binder further comprises one or more high molecular weight biopolymers.

10. The composition of any one of claims 1-9, wherein the composition comprises 1-10% by weight of the binder.

11. The composition of any one of claims 1-10, wherein the one or more charring agents is pentaerythritol (PER), dipentaerythritol, pentaerythritol (Di-PER), tripentaerythritol (Tri_PER), starch, sucrose, sorbitol, tannic acid, glucose, polyols, or combinations thereof.

12. The composition of any one of claims 1-11, wherein the composition comprises 1-20% by weight of the one or more charring agents.

13. The composition of any one of claims 1-12, wherein the one or more barrier-forming agents is a graphene, an expandable graphite, a graphitic carbon nitride, a mineral filler, mica, a nanomaterial, a nanoclay, or combinations thereof.

14. The composition of claim 13, wherein the nanomaterial or the mineral filler are modified with thermally stable components sandwiched with intumescent active agents.

15. The composition of claim 14, wherein the thermally stable component is melamine, nanoclay, expandable graphite, graphene, or combinations thereof.

16. The composition of claim 13, wherein the nanoclay is Bentonite, Organoclay, Montmorillonite.

17. The composition of claim 13, wherein the graphene is graphene nanosheets, graphene oxide, graphene nanocomposite or graphene quantum dot.

18. The composition of claim 17, wherein the graphene nanocomposite is one or more of polyaniline, metal oxides decorated graphene.2690507419.

119. The composition of claim 13, wherein the mineral filler is talc, calcium carbonate, lamellar kaolin, mica, barytes (barium sulfate), silica, glass microbeads, alumina, pumice, or zeolite.

20. The composition of any one of claims 1-19, wherein the composition comprises 1-10% by weight of the one or more barrier-forming agents.

21. The composition of any one of claims 1-20, wherein the pH modifier is a metal hydroxide, sodium carbonate, calcium carbonate, sodium bicarbonate, aminomethyl propanol (AMP), or combinations thereof.

22. The composition of any one of claims 1-21, wherein the composition comprises 0.1-2% by weight of the pH modifier.

23. The composition of claim 1 or 2, wherein the composition comprises nanoclays, vinyl acetate ethylene (VAE), and redispersible polymer powder (RPP) as a plasticizer to maintain film flexibility during drying and to prevent island formation and sagging of the gel on application to the substrate.

24. The composition of any one of claims 1-23, wherein the transport phase and the activation phase synergistically react to form a stable barrier char upon exposure to fire.

25. The composition of any one of claims 1-24, wherein the intumescent gel is non-toxic, environmentally friendly, and does not emit toxic emissions.

26. The composition of any one of claims 1-25, wherein the transport phase has a viscosity of <100 cP to allow fluid flow through a hose without pressure drag, and wherein the activation phase has a gel viscosity to allow adhesion and coating to a substrate.

27. The composition of any one of claims 1-26, wherein the intumescent gel composition has a wet state and a dry state, and wherein the intumescent gel composition provides at least 30 days of fire protection in the dry state.

28. The composition of any one of claims 1-26, wherein the intumescent gel composition has a wet state and a dry state, and wherein the intumescent gel composition provides up to 3 days of fire protection in the wet state.2790507419.

129. The composition of claim 28, wherein the intumescent gel composition is rehydratable to extend the wet state of the composition and to provide up to 30 days of fire protection in the wet state.

30. The composition of any one of claims 1-29, wherein the composition is washable from the substrate if not exposed to fire.

31. The composition of any one of claims 1-30, wherein application of the composition to a non- porous glass substrate prevents shattering when exposed to flames of approximately 700 °C.

32. A method for protecting a substrate from fire, comprising:a. conveying the transport phase of the composition of claim 1 or 2 through a hose line to the substrate location;b. adding the activation phase of the composition of claim 1 to the transport phase at the outlet of the hose line and before application of the composition to the substrate; and c. applying the intumescent gel composition to the substrate;wherein, addition of the activation phase activates crosslinking with the transport phase to form the intumescent gel upon application to the substrate.

33. The method of claim 32, wherein the intumescent gel composition is rapidly deployable to the substrate location under immediate threat of fire by spray application.

34. The method of claim 33, wherein the fire is a wildfire.

35. The method of claim 33, wherein the substrate location is a structure adjacent to a structural fire.

36. The method of claim 32, further comprising washing the intumescent gel composition off the substrate if not exposed to fire.

37. The method of claim 36, wherein the intumescent gel composition is washed off the substrate using coagulants.

38. The method of claim 37, wherein the coagulants is one or more of CaCl2, AI(OH)3, Ca(OH)2.2890507419.

139. The method of any one of claims 32-38, wherein the intumescent gel composition provides at least 30 days of fire protection after drying on the substrate.

40. The method of any one of claims 32-38, wherein the intumescent gel composition provides up to 3 days of fire protection before drying on the substrate.

41. The method of claim 40, wherein fire protection is extended to up to 30 days by rewetting the intumescent gel composition.90507419.1

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