Transparent Intumescent Coating Using Polymer Carbon Donation
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Solution Overview
Problem
Conventional intumescent coating masses are heavy, expensive to produce, and lack transparency, making them unsuitable for lightweight applications like aviation and textiles, where they also restrict surface design due to their opacity.
Innovation Solution
An intumescent system where the polymer material itself acts as a carbon donor, eliminating the need for a separate carbon-donor component in the coating mass, allowing for a thin, transparent application that utilizes synthetic organic fibers as carbon donors, reducing weight and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional intumescent coating masses are applied in a sufficiently thick layer to ensure effectiveness, then flame retardancy is improved, but weight increases
Solution Approach 1:
The patent combines the carbon donor function with the polymer substrate itself, eliminating the need for separate carbon donor additives in the coating mass. The polymer provides both structural support and carbon for char formation, reducing coating thickness requirements and overall weight while maintaining flame retardancy
Solution Approach 2:
The patent changes the chemical composition parameters of the coating mass by removing carbon donor components and relying on the polymer substrate's carbon content. This parameter change allows for thinner coating applications that still achieve effective flame protection, thereby reducing weight
2Reliability
If conventional intumescent coating masses are used, then flame protection is provided, but transparency is lost
Solution Approach 1:
The patent extracts and removes opaque fillers and carbon donor additives from the coating mass formulation. By taking out these opacity-causing components and relying solely on the transparent polymer substrate and clear coating binders, the coating maintains high transparency while still providing effective flame protection through intumescence
Solution Approach 2:
The patent achieves colorless and transparent coating by selecting transparent polymers and clear coating components. The coating mass is formulated without pigments or opaque fillers, allowing light to pass through while the intumescent mechanism remains intact for flame protection
3Reliability
If conventional intumescent coating masses are used, then flame retardancy is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the substrate and coating functional roles by making the polymer substrate itself serve as the carbon donor. This eliminates the need for separate carbon donor additives and simplifies the coating formulation to essential components only (binders, flame retardants, foaming agents), reducing manufacturing complexity
Solution Approach 2:
The patent makes the polymer substrate multi-functional by having it serve both as the structural base material and as the carbon donor for char formation. This universality eliminates the need for separate carbon donor components, simplifying the overall system and manufacturing process while maintaining flame retardancy
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 system achieves excellent transparency and flame retardancy with reduced weight, suitable for textiles and other lightweight applications, maintaining the appearance of the surface while providing effective flame protection.
Implementation Method 1
the polymer material generates a carbon-donor component
Implementation Method 2
create a carbon foam when heat is applied. The carbon foam has a 10 to 100-fold volume in comparison to the original thickness of the coating mass
Implementation Method 3
The carbon foam has a 10 to 100-fold volume in comparison to the original thickness
Implementation Method 4
Due to its very low heat conducting capacity, the foam protects a material which is coated with it from the effects of flames
Data Source
AI summary
The invention relates to an intumescent body, made from a non-intumescent polymer material providing the form of the body and a coating material applied to the polymer material. According to the invention, the polymer material together with the coating material provides an intumescent system in which the polymer material forms a carbon-donor material.