GO/MOF Intumescent Coating Additive for Stable Fire-Protective Char

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Solution Overview

Problem

Existing intumescent coatings provide limited protection to metallic substrates before thermal decomposition and suffer from mechanical performance issues, dimensional stability, hazardous fumes, and heat transmission, necessitating improved additives.

Innovation Solution

A hybridized graphene oxide (GO) and metallic organic framework (MOF) nanocomposite is synthesized with a high concentration of Ce3+ or Zn2+/La3+ doping, forming a GO/MOF nanocomposite that enhances char mechanical performance, adsorbs noxious fumes, and creates an oxygen barrier, used in intumescent coatings with melamine-ammonium polyphosphate, pentaerythritol, and acrylic resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If neat resin coatings are used for fire protection, then the coating can be applied to substrates, but the protection is limited before thermal decomposition at around 300 degrees C

Engineering Contradiction:

Improvefire protection effectivenessVSAvoidthermal decomposition temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses a composite material system consisting of intumescent resin coating combined with specific additives (ammonium polyphosphate, melamine, pentaerythritol, and hydroxide additives) to create a multi-component fire protection system that maintains structural integrity at temperatures where neat resin would decompose

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If known additives like ammonium polyphosphate are incorporated to enhance fire-retardant properties, then flame spread rate is reduced, but mechanical performance and dimensional stability of the char deteriorate

Engineering Contradiction:

Improveflame spread rateVSAvoidmechanical performance of char

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent modifies the chemical composition parameters of the additive system by incorporating specific hydroxide additives (such as magnesium hydroxide, calcium hydroxide) in controlled amounts to adjust the decomposition temperature and mechanical properties of the resulting char, achieving both fire retardancy and structural stability

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If known additives are used to enhance fire-retardant properties, then ignition resistance is improved, but release of noxious fumes increases

Engineering Contradiction:

Improveignition resistanceVSAvoidnoxious fumes

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent converts potentially harmful fume-generating decomposition reactions into beneficial processes by using hydroxide additives that decompose to release water vapor instead of noxious fumes, while still providing fire retardancy through endothermic decomposition and char formation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Temperature

If known additives are incorporated to improve fire-retardant properties, then heat transmission is reduced, but environmental hazard increases due to hazardous materials

Engineering Contradiction:

Improveheat transmissionVSAvoidenvironmental hazard

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces persistent hazardous materials (such as polybrominated diphenyl ethers) with environmentally benign hydroxide additives that decompose completely during fire exposure, providing fire protection without leaving toxic residues in the environment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 GO/MOF nanocomposite improves the fire-retardant properties by increasing mechanical stability, reducing flame spread, and adsorbing combustion gases, offering a more environmentally friendly alternative to hazardous materials like polybrominated biphenyls and polybrominated diphenyl ether.

Implementation Method 1

the metallic organic framework is known to have very high surface area and high porosity with a large capacity for gas absorption, thus fumes that may be generated through the char burning can be adsorbed thus reducing noxious vapors produced by the flames

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

Intumescent materials swell when exposed to heat, with subsequent volume increase but density decrease

Methodology Applied

Scientific EffectIntumescent swelling: Thermal Expansion

Implementation Method 3

Graphene oxide, when reduced to reduced graphene oxide, emits water and other oxygenated small molecules which can reduce the spread of flame

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 4

Reduced graphene oxide may also create an impervious barrier to block the spread of flame through the material and produce an oxygen barrier to restrict combustion

Methodology Applied

Scientific EffectPhysical barrier formation:

Implementation Method 5

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250388764A1Hybridized graphene family / metallic organic frameworks nanocomposite composition, and use as additive for intumescent coatings

Publication Date: 2025.12.25 ZENTEK LTD

AI summary

A hybridized graphene oxide and metallic organic framework nanocomposite, and an intumescent coating composition comprising the nanocomposite as an additive.