Intumescent Coatings via Acrylate-Amine Michael Addition
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Solution Overview
Problem
Existing intumescent coatings face limitations in curing speed, mechanical strength, UV resistance, and hazardous formulations, particularly in epoxy-based compositions which are restricted by slow curing, mechanical weakness, and chemical resistance, and PMMA-based compositions which have issues with storage and odor.
Innovation Solution
A combination of acrylate compounds and amine compounds with a specific functional filler package, which allows for fast curing, improved UV resistance, and safer handling, avoiding hazardous components like peroxides and isocyanates, using a Michael addition reaction for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy-based intumescent coatings are used, then mechanical strength and chemical resistance are improved, but curing speed is slow
Solution Approach 1:
The patent changes the chemical parameters of the coating formulation by using acrylate compounds with specific functional groups (carboxyl, phosphoric acid, or sulfonic acid) in combination with amine compounds. This parameter change enables fast curing through Michael addition chemistry while maintaining the mechanical strength and chemical resistance associated with epoxy-based systems.
Solution Approach 2:
The patent creates a composite coating system that combines acrylate compounds, amine compounds, and intumescent additives in a single formulation. This composite approach integrates the fast curing characteristics of acrylate-amine systems with the fire protection functionality of intumescent coatings, achieving both rapid productivity and desired performance properties.
2Productivity
If PMMA-based intumescent compositions are used, then curing speed and filler loading level are improved, but hazardous components and pungent odor are introduced
Solution Approach 1:
The patent employs acrylate compounds that cure rapidly through Michael addition with amine compounds, achieving fast curing without requiring hazardous peroxides or isocyanates. The formulation uses readily available, inexpensive raw materials that provide adequate pot life for application while eliminating the need for storage of hazardous substances.
Solution Approach 2:
The patent converts the potential harm of slow curing in epoxy systems and hazardous components in PMMA systems into benefits by utilizing the fast, safe Michael addition reaction between acrylate and amine groups. This reaction provides rapid curing without the harmful byproducts or storage issues associated with traditional intumescent coating systems.
3Ease of operation
If single-pack waterborne coatings are used, then ease of application is improved, but mechanical weakness and chemical resistance are introduced
Solution Approach 1:
The patent changes the chemical parameters by incorporating acid-functional acrylate compounds that react with amine compounds to form crosslinked networks. This parameter change enables the coating to achieve enhanced mechanical strength and chemical resistance while maintaining the ease of application characteristic of single-pack formulations.
Solution Approach 2:
The coating formulation is designed to self-cure through the Michael addition reaction between acrylate and amine groups without requiring separate hardener components or complex application procedures. The single-pack formulation applies easily while the chemistry provides self-reinforcing crosslinking that develops strength and chemical resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides intumescent coatings with fast curing speed, mechanical robustness, UV resistance, and safer handling, suitable for various applications including fire protection, corrosion protection, and flooring, without the need for special equipment or raw material changes, while maintaining cost-effectiveness and environmental safety.
Implementation Method 1
the combination of the different components allows for producing intumescent coating compositions having a fast curing speed, good UV resistance, and light stability, which is favorable when compared with known epoxy-based compositions. Without being bound by theory, it is believed that this is inter alia due to the relatively fast Michael addition reaction between the acrylate compound AcC and the amine group(s) of the amine compound AmC, resulting in acrylate-amine adducts.
Data Source
AI summary
A fast curing intumescent coating composition comprises a component A and a component B, wherein the component A comprises at least one (meth)acrylate compound AcC having one or more acryloyl groups (CH2=CHCO-) and/or methacryloyl groups (CH2=C(CH3)CO-) in a molecule; and wherein the component B comprises an amine compound AmC comprising at least one amine group selected from primary amine groups, secondary amine groups and/or blocked amine groups; wherein the intumescent coating composition further comprises: - from 10 - 70 wt.-%, based on the total weight of the intumescent coating composition, of at least one acid source; wherein the sum of the acrylate compound AcC and the amine compound AmC (AcC + AmC) is from 10 - 50 wt.-%, based on the total weight of the intumescent coating composition; and wherein the molar ratio of the acryloyl groups (CH2=CHCO-) and methacryloyl groups (CH2=C(CH3)CO-) of the AcC and the potentially present epoxy groups of the at least one epoxy resin EP to the amine groups of the amine compound AmC is from 0.5 - 1.5.