Intumescent Coating Composition for Stable Fire-Resistant Char Foam
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Solution Overview
Problem
Existing intumescent coatings struggle to form a mechanically stable foam char layer with desirable fire resistance, and existing multi-layer coating systems complicate the application process.
Innovation Solution
A novel intumescent coating composition using a combination of glycoluril or alkylated glycoluril and aminotriazine compounds, along with polymeric binders, ammonium salts of phosphoric acids, carbohydrates, and optional pigments, to create a robust and mechanically stable char foam layer without altering the standard coating procedure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coating is expanded to improve fire resistance performance, then the insulating properties increase, but the mechanical strength decreases making it easier to crush
Solution Approach 1:
The patent employs a composite blowing agent system combining glycoluril (or alkylated glycoluril) with at least one aminotriazine compound. This composite approach creates a synergistic effect where the interaction between different blowing agents produces a foam char layer with both high expansion for fire resistance and enhanced mechanical strength through improved cellular structure and cross-linking, resolving the contradiction between expansion and strength
2Reliability
If a bilayer coating system is used to achieve strength/performance balance, then the fire resistance and mechanical strength improve, but the coating procedure becomes complicated
Solution Approach 1:
The patent merges the functions of multiple blowing agents (glycoluril/alkylated glycoluril and aminotriazine compound) into a single coating composition. This unified approach combines the benefits of different blowing mechanisms and chemical reactions within one layer, achieving both mechanical stability and fire resistance performance without requiring separate coating layers or complex multi-step procedures
3Stability of the object's composition
If specific amounts of metal/metalloid atoms from multiple sources are added to balance strength and performance, then the foam char stability improves, but the coating recipe becomes complex
Solution Approach 1:
The patent extracts and eliminates the need for complex metal/metalloid atom combinations by using organic blowing agents (glycoluril and aminotriazine compounds) that achieve foam char stability through their molecular structure and decomposition characteristics rather than relying on multiple metal sources. This simplifies the coating recipe while maintaining mechanical 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 forms a durable char foam layer with enhanced mechanical stability and fire resistance, maintaining structural integrity under heat exposure, as evidenced by superior compressive strength and fire resistance times.
Implementation Method 1
Blowing agents decompose in a fire, releasing gases that cause the coating to expand and form a foam-like structure
Implementation Method 2
Blowing agents decompose in a fire, releasing gases that cause the coating to expand
Implementation Method 3
certain foam-forming substance(s) acting as acid-generating catalyst
Data Source
AI summary
An intumescent coating composition and a coated substrate are described. The intumescent coating composition comprises: (a) a blowing agent comprising glycoluril or an alkylated glycoluril and at least one aminotriazine compound or salts thereof; (b) a polymeric binder; (c) ammonium salts of phosphoric acids and/or polyphosphoric acids as foam-forming substance; (d) carbohydrates as carbon-forming substance; (e) optionally, at least one pigment; and (f) optionally, at least one solvent.