Phosphate Ceramic Coatings with Aerogel for Fire and Insulation
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Solution Overview
Problem
Existing fire-resistant coatings lack simultaneous insulation properties and are not easily sprayable, leading to uneven and thick applications, which is a challenge in achieving both fire resistance and insulation in building materials like structural insulated panels (SIPs).
Innovation Solution
A phosphate-based ceramic coating incorporating aerogel particles, which enhances sprayability and surface properties, providing both fire-resistant and insulating properties by using an acid-base reaction between acidic phosphate and alkaline earth metal oxide/hydroxide, allowing for thin, even, and flexible coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art phosphate-based ceramic coatings are applied, then fire resistance is improved, but sprayability deteriorates and coating uniformity worsens
Solution Approach 1:
The patent modifies the chemical composition parameters of the coating formulation by incorporating specific phosphate binders and ceramic particles in controlled ratios, along with defoamers and dispersants, to achieve optimal sprayability while preserving fire resistance. The viscosity and rheological properties are adjusted through parameter optimization to enable proper spray application.
Solution Approach 2:
The invention creates a composite coating material combining phosphate binders with ceramic particles (such as perlite, vermiculite, or glass beads) in a controlled matrix. This composite structure integrates the fire-resistant properties of ceramics with the sprayable characteristics of phosphate-based binders, resolving the contradiction between fire performance and application ease.
2Reliability
If prior art phosphate-based ceramic coatings are applied, then fire resistance is improved, but coating thickness uniformity worsens
Solution Approach 1:
The formulation parameters are optimized to control coating flow and leveling characteristics. The phosphate binder system is adjusted to provide appropriate open time and reology control, enabling uniform coating thickness during spray application while maintaining fire-resistant performance.
Solution Approach 2:
Dispersants and defoamers are introduced as intermediary substances to mediate between the ceramic particles and phosphate binder, ensuring homogeneous distribution and preventing coating defects that would lead to thickness non-uniformity. These intermediaries facilitate smooth spray application and even coating formation.
3Use of energy by stationary object
If insulation materials are incorporated into fire resistant coatings, then insulation properties are improved, but coating thinness and sprayability deteriorate
Solution Approach 1:
The patent utilizes porous ceramic particles such as perlite or vermiculite as the insulation material. These materials provide excellent thermal insulation properties with low density, allowing them to be incorporated into the sprayable coating formulation without significantly increasing viscosity or compromising sprayability. The porous structure delivers high insulation value in thin coating layers.
Solution Approach 2:
The coating is formulated as a composite material where lightweight porous insulation particles are distributed within a phosphate-based binder matrix. This composite structure achieves the desired insulation performance while maintaining the sprayable consistency required for easy application, resolving the contradiction between insulation capability and application ease.
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 coating achieves excellent thermal insulation and fire resistance in thin layers, maintaining flexibility and compatibility with existing building materials, while allowing for easy application and processing like conventional paints, with improved E-modulus and tensile strength.
Implementation Method 1
the aerogel particles that are comprised as necessary components in the phosphate-based ceramic coatings according to the invention. These aerogel particles bestow the phosphate-based ceramic coatings of the invention with remarkable insulation properties
Implementation Method 2
providing both fire-resistant and insulating properties by using an acid-base reaction between acidic phosphate and alkaline earth metal oxide/hydroxide
Data Source
AI summary
The invention provides phosphate-based ceramic coatings comprising aerogel particles, in particular such that are obtainable by reacting a component mixture A with a component mixture B, wherein component mixture A comprises water and acidic phosphate; and component mixture B comprises water and alkaline oxide and/or hydroxide; and wherein component mixtures A and/or B comprise aerogel particles. Further, the invention provides a method for coating a substrate with a sprayable phosphate-based ceramic coating which comprises the steps of (I.) separately providing component mixtures A and B, (II.) mixing component mixtures A and B; and (III.) spraying the mixture obtained in step II. onto the substrate to obtain a layer of phosphate-based ceramic coating comprising aerogel particles. The invention also provides a laminate comprising a protective layer and a layer of phosphate-based ceramic coating comprising aerogel particles as well as practical uses of such coatings and laminates, e.g. as fire-protection and insulation material, and products comprising the coatings and laminates of the invention.