Epoxy-Thiol Fire Retardant Coating for Steel Structures
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Solution Overview
Problem
Current insulating layer-forming compositions for fire retardation, particularly on steel structures, face challenges such as long curing times, labor-intensive application processes, material inefficiency, and health risks associated with certain binder compounds, while also requiring thick layers for effective fire resistance.
Innovation Solution
A composition comprising an epoxy resin, a thiol compound as a curing agent, and an intumescent additive, which allows for fast curing at low temperatures, reduced material usage, and improved adhesion and cohesion with substrates, enabling effective fire retardation with thinner layers and minimizing health risks through the avoidance of toxic compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-based or water-based intumescent coatings are applied, then the coating can be applied and will form an insulating layer, but the curing times are long and multiple layers must be applied, increasing labor time and costs
Solution Approach 1:
The patent changes the chemical parameters of the binder system by using 100% solids epoxy-thiol composition instead of solvent-based or water-based systems. This eliminates the drying phase and enables fast curing through chemical reaction, reducing curing time from days to minutes while maintaining fire resistance performance
Solution Approach 2:
The patent replaces the physical drying mechanism (evaporation of solvent or water) with a chemical curing mechanism (polymerization reaction between epoxy and thiol groups). This substitution eliminates the need for prolonged drying time and multiple coating passes, achieving fast curing while maintaining coating integrity
2Productivity
If epoxy-amine systems are used for fast curing, then curing time is reduced, but the binder forms a stable rigid polymer matrix that hinders foam formation and requires processing temperatures up to +70 deg. C., increasing labor intensity and costs
Solution Approach 1:
The patent changes the chemical composition parameters by replacing amine-based curing agents with thiol-based curing agents. This parameter change maintains fast curing capability while lowering the softening range of the polymer matrix, enabling application at lower temperatures without sacrificing curing speed
Solution Approach 2:
The patent utilizes the phase transition characteristics of thiol-epoxy polymerization to achieve fast curing at low temperatures. The thiol-epoxy reaction proceeds rapidly at ambient temperatures, forming a crosslinked network that provides both fast curing and low-temperature applicability, eliminating the need for heated application chambers
3Reliability
If thick coating layers are applied to achieve required fire resistance periods, then fire resistance is improved, but the material consumption increases, particularly for closed profiles needing twice the amount
Solution Approach 1:
The patent changes the chemical reactivity parameters of the binder system through the use of thiol-epoxy composition. This highly reactive system forms a crosslinked network that enhances coating cohesion and adhesion, allowing thinner application layers to achieve the same fire resistance performance, thereby reducing material consumption
Solution Approach 2:
The patent creates a composite coating system combining epoxy-thiol binder with intumescent additives. This composite formulation achieves superior fire resistance in thinner layers through the synergistic effect of the crosslinked polymer matrix and intumescent components, reducing overall material consumption while maintaining protective performance
4Ease of manufacture
If conventional binder systems are used, then the coating can be applied, but health risks arise from toxic compounds such as amines or amine mixtures
Solution Approach 1:
The patent replaces toxic amine-based curing agents with non-toxic thiol-based curing agents. This substitution eliminates health risks associated with amine toxicity while maintaining the functional performance of the coating system, providing a safer working environment without sacrificing manufacturing ease
Solution Approach 2:
The patent converts the potentially harmful amine compounds into beneficial thiol compounds. The thiol-epoxy reaction provides the same curing functionality as amine-epoxy systems but without the toxic side effects, transforming a harmful chemical system into a safe one while preserving coating performance
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 significantly reduces curing times, minimizes material usage, and enhances the insulating effect with a high degree of filling, maintaining mechanical stability and adhesion, thus providing efficient fire retardation with improved safety and reduced application costs.
Implementation Method 1
a second constituent containing at least one thio compound as a curing agent
Implementation Method 2
a third constituent containing an intumescent additive
Implementation Method 3
This foam layer has high heat insulating properties, as a function of the composition, and, as a result, delays the temperature rise of the component
Implementation Method 4
the binder is primarily cured by oxidation reactions and polymerization reactions
Data Source
AI summary
Described is an insulating layer-forming composition, which contains a binder based on epoxy-thiol. The inventive composition, its rate of expansion ratio is relatively high, allows coatings having the layer thickness, required for the respective period of fire resistance, to be applied in a simple and fast manner, while at the same time the layer thickness is reduced to a minimum and yet a high insulating effect can be achieved. The composition of the invention is particularly suitable for fire protection, in particular as a coating of metallic and non-metallic substrates, such as steel components, like columns, beams, trusses, in order to increase the period of fire resistance.