Multilayer Intumescent Coating for Fine-Pore Fire Insulation
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Solution Overview
Problem
Existing intumescent fire-retardant coating materials suffer from poor thermal insulation due to large pores and high thermal conductivity, limiting their fireproof performance.
Innovation Solution
A multilayer composite intumescent fire-retardant coating material is developed, comprising a bottom layer with a physical expansive agent and a surface layer with a gas-foaming expansive agent, which reduces pore size and enhances thermal insulation by combining their expanding effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expanded graphite is added to improve expansion layer strength, then the expansion layer has high strength, but the thermal insulation performance deteriorates due to high thermal conductivity coefficient
Solution Approach 1:
The coating is divided into multiple layers with different functions: the bottom layer contains expanded graphite for structural strength and pore filling, while the surface layer uses gas-foaming expansive agent for thermal insulation. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The patent combines different expansive agents (physical expanded graphite and chemical gas-foaming agents) in a composite coating system. The composite structure integrates the high strength of graphite-filled expansion layers with the superior thermal insulation of gas-foamed surface layers, achieving both mechanical and thermal performance requirements.
2Reliability
If the expansion rate is increased to improve fireproof performance, then the expansion layer provides better protection, but large pores form causing poor adhesion between expansion layer and basic material
Solution Approach 1:
The coating system is segmented into a bottom layer applied to the basic material and a surface layer applied afterward. The bottom layer with physical expansive agent ensures good adhesion and fills pores, while the surface layer with gas-foaming agent provides high expansion rate for fireproof performance without compromising adhesion.
Solution Approach 2:
The bottom layer is applied and cured first to create a stable, well-adhered base layer that fills pores and provides mechanical anchoring. This preliminary action ensures that subsequent high-rate expansion of the surface layer does not cause delamination, as the foundation is already securely in place.
3Strength
If epoxy resin with high compactness is used to improve adhesion, then the coating adheres well to the basic material, but large pores form in the expansion layer reducing thermal insulation
Solution Approach 1:
The coating is segmented into two functional layers: the bottom layer uses high compactness epoxy resin for strong adhesion and pore filling, while the surface layer uses gas-foaming expansive agent to create fine-pored insulating structure. This segmentation resolves the conflict between adhesion requirements and thermal insulation requirements.
Solution Approach 2:
Different regions of the coating have different material compositions optimized for their specific functions. The bottom layer near the substrate has high compactness for adhesion, while the surface layer has controlled porosity for thermal insulation, achieving local optimization of both properties.
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 multilayer coating material improves thermal insulation and fireproof performance by reducing pore size and enhancing the compactness of the expansion layer, thereby slowing down thermal transfer and delaying material failure.
Implementation Method 1
a bottom fire-retardant coating material containing a physical expansive agent
Implementation Method 2
a surface fire-retardant coating material containing a gas-foaming expansive agent
Implementation Method 3
improves thermal insulation and fireproof performance by reducing pore size and enhancing the compactness of the expansion layer, thereby slowing down thermal transfer
Data Source
AI summary
Disclosed are a multilayer composite intumescent fire-retardant coating material, a preparation method therefor, and a method of using the same, relating to the technical field of intumescent fire-retardant coating materials. The coating material comprises a bottom fire-retardant coating material and a surface fire-retardant coating material, and a composite method is a single layer or presents an ABAB . . . type. The bottom fire-retardant coating material contains a physical expansive agent. The surface fire-retardant coating material contains a gas-foaming expansive agent. By fully utilizing the filling effect of the physical expansive agent and the expanding effect of the gas-foaming expansive agent, the size of pores formed in the expansion layer under the fire is substantially reduced, which not only improves the compactness and strength of the expansion layer but also improves the thermal insulation performance of the expansion layer.