Intumescent coatings
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Solution Overview
Problem
Conventional intumescent coatings are not durable for weathering and are too viscous to apply at low thicknesses, posing challenges for effective fire protection, especially for batteries like lithium ion batteries that are vulnerable to thermal runaways.
Innovation Solution
A coating composition comprising an epoxy resin as the film-forming component, a phosphate source, a borate source, an aluminum source, and TiO2, with specific weight percentages to form a self-supporting film or sheet that provides desirable char formation and adhesion to substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional intumescent coatings are used, then fire protection is provided, but the coatings are not durable for weathering and are too viscous to apply at low thicknesses
Solution Approach 1:
The patent modifies the chemical composition parameters of the intumescent coating by incorporating specific ratios of epoxy resin, phosphate source, borate source, aluminum source, and TiO2. This parameter optimization reduces viscosity to enable low-thickness application while maintaining fire protection durability and weathering resistance
Solution Approach 2:
The invention creates a composite intumescent coating material combining epoxy resin as the film-forming component with phosphate, borate, aluminum, and TiO2 sources. This composite structure achieves both improved applicability through reduced viscosity and enhanced reliability for fire protection, resolving the technical contradiction between ease of operation and reliability
2Reliability
If the coating forms a thick char to protect against direct flame blow, then fire protection is improved, but the char may crack and lose integrity
Solution Approach 1:
The patent incorporates TiO2 pigment particles distributed throughout the coating composition to locally reinforce the char structure. This local quality enhancement prevents cracking while maintaining the overall thickness needed for fire protection, resolving the contradiction between fire protection effectiveness and char integrity
Solution Approach 2:
The composite formulation combining epoxy resin with phosphate, borate, aluminum, and TiO2 sources creates a char with improved structural integrity. The TiO2 reinforcement within the composite matrix prevents cracking during thermal expansion, maintaining both protection effectiveness and structural stability
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 composition achieves desirable char formation with good adhesion to substrates, even under intense heat, effectively protecting substrates from fire damage and maintaining integrity during direct flame exposure.
Implementation Method 1
Intumescent coatings have been used for a variety of structural applications to protect against both cellulosic and hydrocarbon fires. Such coatings offer protection by forming a carbonaceous char upon exposure to intense heat.
Implementation Method 2
The char that forms in a fire provides optimal protection when the char expands to optimum thickness
Data Source
AI summary
Intumescent coating compositions comprising TiO2 in an amount of 5-20 wt %, a phosphate source in an amount of 20-55 wt %, based on total solid weight and a borate source, aluminum source and/or silica source, are disclosed, as are methods for using such compositions and substrates coated with same.