Water-Based Epoxy Coating for Fireproofing Drying Control
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Solution Overview
Problem
Existing fireproofing coatings fail to provide a uniform application on wet fireproofing materials due to high water content, leading to non-uniform coatings and inadequate durability and early drying issues.
Innovation Solution
A water-based epoxy coating composition comprising an epoxy resin and an amine hardener, applied within one hour of fireproofing material application, which forms a uniform and effective coating despite high water content, controlling drying and shrinkage rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-aqueous (organic based) sealant is applied to fireproofing material with high water content, then the coating provides durability enhancement and acts as a sealant, but the coating becomes non-uniform due to pooling or beading up
Solution Approach 1:
The patent changes the key parameter of the coating composition from non-aqueous to water-based, making it compatible with the high water content environment of freshly applied fireproofing material. This parameter change eliminates the pooling and beading issues while maintaining sealant functionality and durability enhancement.
Solution Approach 2:
The water-based coating composition creates a homogeneous mixture with the water-containing fireproofing material surface, ensuring uniform distribution and coating formation. This homogeneity principle resolves the non-uniform coating issue while preserving the protective functions.
2Productivity
If coating is applied soon after fireproofing material application to reduce scaffolding costs and construction delays, then productivity and cost efficiency improve, but the coating fails to provide uniform coverage due to high water content
Solution Approach 1:
The invention changes the coating composition from non-aqueous to water-based, enabling application on wet surfaces immediately after fireproofing material application. This resolves the contradiction by allowing prompt coating application for productivity improvement while achieving uniform coverage through water-based compatibility.
3Strength
If prompt coating is applied to reduce early drying rate and improve curing, then the curing and strength development improve, but non-aqueous coatings cannot achieve uniform application on wet surfaces
Solution Approach 1:
The patent changes the coating from non-aqueous to water-based formulation, enabling uniform application on wet fireproofing surfaces. This allows prompt coating application that simultaneously achieves uniform coverage and reduces early drying rate for improved curing and strength development.
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 water-based epoxy coating composition ensures a uniform and durable coating, reducing drying and shrinkage rates by 10-50% and preventing water ingress, thereby enhancing the strength and longevity of fireproofing materials.
Implementation Method 1
The coating compositions are effective to control the drying rate and shrinkage of fireproofing materials
Implementation Method 2
The coating compositions are effective to control the drying rate and shrinkage of fireproofing materials
Implementation Method 3
preventing water ingress, thereby enhancing the strength and longevity of fireproofing materials
Data Source
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AI summary
The present disclosure relates to coating compositions, kits, and methods of applying the same, for use with fireproofing materials. The coating compositions are effective to control the drying rate and shrinkage of fireproofing materials. The coating compositions are also able to be applied to fireproofing materials shortly after these materials have been applied to a substrate.