US20100190886A1 - Resin system for intumescent coating with enhanced metal adhesion - Google Patents

Resin system for intumescent coating with enhanced metal adhesion Download PDF

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Publication number
US20100190886A1
US20100190886A1 US12/669,573 US66957308A US2010190886A1 US 20100190886 A1 US20100190886 A1 US 20100190886A1 US 66957308 A US66957308 A US 66957308A US 2010190886 A1 US2010190886 A1 US 2010190886A1
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meth
acrylate
intumescent coating
resin system
coating according
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US12/669,573
Inventor
Guenter Schmitt
Peter Neugebauer
Sybille Scholl
Heike Heeb
Peter Reinhard
Gilbert Kuehl
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Evonik Roehm GmbH
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Evonik Roehm GmbH
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Assigned to EVONIK ROEHM GMBH reassignment EVONIK ROEHM GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SCHMITT, GUENTER, NEUGEBAUER, PETER, KUEHL, GILBERT, SCHOLL, SYBILLE, HEEB, HEIKE, REINHARD, PETER
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
    • C09D4/06—Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/18—Fireproof paints including high temperature resistant paints
    • C09D5/185—Intumescent paints
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y10T428/31895—Paper or wood

Definitions

  • the invention relates to a resin system for an intumescent coating with improved metal adhesion.
  • Intumescent coatings are used to protect steel, and steel girders, from fire damage in construction.
  • Conventional systems are provided with a variety of intumescent adjuvants, which when exposed to heat react together and form an insulating foam exhibiting low thermal conduction. This foam reduces the heating of the steel and so prolongs the time before the steel loses its supporting function. Additional evacuation time is gained.
  • Known coating systems are based on high molecular mass thermoplastic resins based on acrylates, methacrylates and/or vinyls and require a high solvent or water fraction for application to the corresponding metal surface. This leads to long drying times, in some cases very long, particularly when very thick coats are applied. For reasons of environmental protection, water-based coatings are being used increasingly, but require longer drying times, especially in regions with high atmospheric humidity.
  • the intumescent coating is typically applied on-site during the construction phase. Preference is given, however, to in-shop applications, since these can take place under controlled conditions. In the case of slow drying, however, an impractical cycle time results, because the components cannot be moved until drying is complete.
  • Epoxy-based intumescent coatings are used with preference in the offshore industry. They are distinguished by effective ageing stability and relatively short drying times. Polyurethane systems are a subject of intense investigation. They likewise feature a relatively short drying time and effective water resistance. Here, however, fire tests have had negative outcomes, owing to the poor adhesion of the coating to the steel [Development of alternative technologies for off-site applied intumescent coatings, Longdon, P. J., European Commission [Report] EUR (2005), EUR 21216, 1-141].
  • the object was to provide an improved resin for an intumescent coating.
  • the object moreover, was to provide a process for the production of the resin.
  • the object has been achieved by a resin system for an intumescent coating comprising at least one ethylenically unsaturated monomer component, characterized in that there is at least one polymeric component comprising an acid (meth)acrylate or copolymerizable polyfunctionalized carboxylic acids present.
  • the new resin system as a binder for intumescent coatings has outstanding adhesion properties to metallic surfaces, particularly to steel.
  • the resin system can also be used as a wood coating.
  • the coatings of the invention can be used both on-site and in-shop.
  • the intumescent coatings comprising the new resins dry cure very quickly. Drying times of approximately 1 hour are achieved. Through the addition of more curing agents it is possible to lower the curing time further. Accordingly the preferred in-shop application can take place within acceptable cycle times.
  • Crosslinkers used are more particularly polyfunctional methacrylates such as allyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimetacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, 1,3-butanediol dimethacrylate, 1,4-butanediol dimethacrylate, 1,6-hexanediol dimethacrylate, 1,12-dodecanediol dimethacrylate, glycerol dimethacrylate and trimethylolpropane trimethacrylate.
  • polyfunctional methacrylates such as allyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimetacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, 1,3-butanediol dimethacrylate, 1,4
  • the coating preferably comprises one thermoplastic polymer resin in combination with low molecular mass monomers or oligomers having ethylenically unsaturated double bonds, in the form for example of alpha-beta ethylenically unsaturated carboxylic ester groups such as methacrylate or acrylate groups, for example.
  • the notation (meth)acrylate here denotes not only methacrylate, such as methyl methacrylate, ethyl methacrylate, etc., for example, but also acrylate, such as methyl acrylate, ethyl acrylate, etc., for example, and also mixtures of both.
  • thermoplastic polymer is preferably a (meth)acrylate resin in the form of homopolymer, copolymer and/or terpolymer.
  • a polymer component is a (meth)acrylate polymer.
  • This polymer can be prepared via the polymerization of one or more methacrylate or acrylate monomers, preferably from the group of methyl (meth)acrylates, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate.
  • Co-reagents may be styrene or vinyltoluenes.
  • One particularly preferred thermoplastic polymer is a copolymer of butyl methacrylate and methyl methacrylate.
  • One ethylenically unsaturated monomer component comprises at least one methacrylate or acrylate functionality.
  • One ethylenically unsaturated monomer component is preferably selected from the group of methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate.
  • thermoplastic polymer resins comprises homopolymers, copolymers or terpolymers of vinyl monomers such as styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and/or vinyl esters.
  • Co-reagents may be dienes, such as butadiene, for example.
  • thermoplastic resins form 10%-60% by weight of the resin component of the coating mixture.
  • One polymeric component may comprise methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)-acrylate, isobutyl (meth)acrylate, tert-butyl (meth)-acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxy-propyl (meth)acrylate and/or 2-ethylhexyl (meth)-acrylate.
  • One polymeric component may also comprise a reaction product of one or more dienes with at least one styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and/or vinyl ester.
  • At least one of the liquid monomer components comprises methacrylate functionalities, with particular preference methacrylic esters. If desired it is also possible for an acrylate functionality to be present, preferably acrylic esters.
  • the monomer component is monofunctional, so that the reaction product with an organic peroxide is thermoplastic and melts and flows up to the reaction temperature of the intumescent additives.
  • (meth)acrylic esters are selected from the group of methyl (meth)acrylates, ethyl (meth)-acrylates, n-butyl (meth)acrylates, isobutyl (meth)-acrylates, tert-butyl (meth) acrylates, 2-ethylhexyl (meth)acrylates and mixtures thereof.
  • Methyl methacrylate and 2-ethylhexyl acrylate are particularly preferred.
  • the liquid monomer component forms 30%-60% by weight of the resin component of the coating mixture.
  • the resin component forms 10%-60% by weight, with particular preference 25%-50% by weight, of the coating mixture.
  • Initiators are used in order to cure the liquid coating. Use is made of AZO initiators or organic peroxides. Preferred initiators used are dialkyl peroxides, keto peroxides, peroxy esters, diacyl peroxides, hydroperoxides and/or peroxy ketals. The initiator is used in amounts of 0.5% to 5%, with particular preference 1%-4% with respect to the overall resin composition.
  • tertiary amines are N,N-dimethylanilines and N,N-dialkyl-p-toluidines.
  • the fraction of the tertiary amines as a proportion of the overall resin mixture is 0.1%-4%, preferably 0.25%-3%.
  • Preferred azo initiators are 2,2-azobis(amidinopropane) dihydrochloride, 2,2-azobis(2-methylbutyronitrile), 2,2-azobis(2-methylpropanenitrile), 2,2-azobis(2,4-di-methylpentanenitrile), and mixtures thereof.
  • a substantial improvement in the adhesion properties of the intumescent coating on metal surfaces is achieved through the addition of acid (meth)acrylates or copolymerizable polyfunctionalized carboxylic acids.
  • the acid (meth)acrylates are preferably selected from the group of dicarboxylic acids, particular preference being given to the use of ⁇ -CEA.
  • Copolymerizable polyfunctionalized carboxylic acids that can be used include all known multiply functionalized carboxylic acids, selection taking place with particular preference from the group of itaconic acids, fumaric acids and maleic acids.
  • Beta-CEA is the Michael product of acrylic acid and is always a mixture of:
  • the acid (meth)acrylates or copolymerizable polyfunctionalized carboxylic acids preferably form a part of the polymeric component of the resin.
  • the object has also been achieved by a process for curing intumescent coatings comprising resin systems according to claim 1 .
  • the process of the invention is characterized in that at least one ethylenically unsaturated monomer component and at least one polymeric component comprising one acid (meth)acrylate or copolymerizable polyfunctionalized carboxylic acids and the customary intumescent auxiliaries and additives, are polymerized by means of free radical polymerization.
  • the intumescent coating comprises specific substances which when exposed to heat react with one another and form a foam for isolation.
  • the coating is composed preferably of 3 components: an acid source, a carbon source and a gas source.
  • the resin component On exposure to heat, the resin component begins to melt.
  • the acid source is activated and is able to react with the other constituents of the coating.
  • the acid source used is, for example, ammonium polyphosphates or polyphosphoric acids, which react with pentaerythritol (carbon source), for example, to form polyphosphoric ester. The breakdown of this ester leads to carbon compounds, which together with foaming agents such as melamine form the desired foam.
  • the intumescent coating ideally comprises at least one acid source such as ammonium polyphosphate, melamine phosphate, magnesium sulphate or boric acid, for example.
  • the intumescent coating mixture comprises a carbon source, such as pentaerythritol and dipentaerythritol and mixtures thereof, for example. Starch and expandable graphite are likewise suitable.
  • the intumescent coating mixture comprises a gas source, such as melamine, melamine phosphate, melamine borate, melamine-formaldehyde, melamine cyanurate, tris(hydroxyethyl)isocyanurate, ammonium polyphosphate or chlorinated paraffin, for example.
  • a gas source such as melamine, melamine phosphate, melamine borate, melamine-formaldehyde, melamine cyanurate, tris(hydroxyethyl)isocyanurate, ammonium polyphosphate or chlorinated paraffin, for example.
  • nucleating agents present.
  • These may be, for example, titanium dioxide, zinc oxide, aluminium oxide, silicon, silicates, heavy metal oxides such as cerium oxide, lanthanum oxide and zirconium oxide, mica or loam.
  • Further adjuvants e.g. zinc borate, glass beads, fibre materials, etc. may be present in the intumescent coating mixture.
  • the fraction of the intumescent components as a proportion of the coating mixture is 40%-85%, preferably 50%-75%.
  • Thixotropic adjuvants can be used in order to improve the rheology, in order to make thick coatings possible in one application step. They are added in amounts of 0%-2%, preferably 0.05%-1%, based on the total amount of the coating.
  • wetting adjuvants or dispersion adjuvants it is also possible for wetting adjuvants or dispersion adjuvants to be added.
  • the organic peroxide Prior to the application of the coating to the metallic surface the organic peroxide is added. This initiates the free-radical reaction in the course of which the liquid coating cures. Typically the cure time is 30 minutes. It can be varied through the amount of initiator and accelerator.
  • the coating can be applied by means of spraying technology, brush, roller, spatula or dipping process.
  • spraying technology brush, roller, spatula or dipping process.
  • a multi-component spraying system it is also possible to use a multi-component spraying system.
  • the metal surface is typically cleaned before the coating is applied, in order to remove processing residues and the like. In some cases primers are applied as well.
  • topcoat for exposed metal surfaces, for example.
  • the thickness should only be between 15 ⁇ m and 250 ⁇ m, in order not to inhibit the intumescent reaction.
  • the outstanding adhesion properties allow the resin system for intumescent coatings, in accordance with the invention, to be applied to other surfaces in need of an intumescent coating.
  • Surfaces of wood, for example, can also be coated.
  • the resin system of the invention is processed using a
  • This airless spray system uses 2 pumps, which with an inlet pressure of 0.35 MPa spray the mixture through the nozzle at approximately 19.3 MPa.
  • the nozzle size is approximately 525-675 ⁇ m in diameter.
  • the adhesion of the coating to the construction steel was determined using a PAT (precision adhesion test equipment, hydraulic adhesion tester) instrument.
  • This figure meets the requirements for a construction steel coating which can be used industrially.
  • a conventional resin system is processed using a Graco Extreme Mix Plural Component Spray System.
  • This airless spray system uses 2 pumps, which with an inlet pressure of 0.35 MPa spray the mixture through the nozzle at approximately 19.3 MPa.
  • the nozzle size is approximately 525-675 ⁇ m in diameter.
  • the adhesion of the coating to the construction steel was determined using a PAT (precision adhesion test equipment, hydraulic adhesion tester) instrument.

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Paints Or Removers (AREA)
  • Polymerisation Methods In General (AREA)
  • Graft Or Block Polymers (AREA)

Abstract

The invention relates to an intumescent coating with improved metal adhesion.

Description

  • The invention relates to a resin system for an intumescent coating with improved metal adhesion.
  • Intumescent coatings are used to protect steel, and steel girders, from fire damage in construction. Conventional systems are provided with a variety of intumescent adjuvants, which when exposed to heat react together and form an insulating foam exhibiting low thermal conduction. This foam reduces the heating of the steel and so prolongs the time before the steel loses its supporting function. Additional evacuation time is gained.
  • Known coating systems are based on high molecular mass thermoplastic resins based on acrylates, methacrylates and/or vinyls and require a high solvent or water fraction for application to the corresponding metal surface. This leads to long drying times, in some cases very long, particularly when very thick coats are applied. For reasons of environmental protection, water-based coatings are being used increasingly, but require longer drying times, especially in regions with high atmospheric humidity.
  • The intumescent coating is typically applied on-site during the construction phase. Preference is given, however, to in-shop applications, since these can take place under controlled conditions. In the case of slow drying, however, an impractical cycle time results, because the components cannot be moved until drying is complete.
  • Epoxy-based intumescent coatings are used with preference in the offshore industry. They are distinguished by effective ageing stability and relatively short drying times. Polyurethane systems are a subject of intense investigation. They likewise feature a relatively short drying time and effective water resistance. Here, however, fire tests have had negative outcomes, owing to the poor adhesion of the coating to the steel [Development of alternative technologies for off-site applied intumescent coatings, Longdon, P. J., European Commission [Report] EUR (2005), EUR 21216, 1-141].
  • The object was to provide an improved resin for an intumescent coating.
  • The object, moreover, was to provide a process for the production of the resin.
  • The object has been achieved by a resin system for an intumescent coating comprising at least one ethylenically unsaturated monomer component, characterized in that there is at least one polymeric component comprising an acid (meth)acrylate or copolymerizable polyfunctionalized carboxylic acids present.
  • Surprisingly it has been found that the new resin system as a binder for intumescent coatings has outstanding adhesion properties to metallic surfaces, particularly to steel.
  • The resin system can also be used as a wood coating.
  • The coatings of the invention can be used both on-site and in-shop.
  • It has been found that the intumescent coatings comprising the new resins dry cure very quickly. Drying times of approximately 1 hour are achieved. Through the addition of more curing agents it is possible to lower the curing time further. Accordingly the preferred in-shop application can take place within acceptable cycle times.
  • It has been found, moreover, that the quick-drying and well-adhering resins for intumescent coatings are also outstandingly suitable for thick coating films, for example 1-5 mm.
  • Crosslinkers used are more particularly polyfunctional methacrylates such as allyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimetacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, 1,3-butanediol dimethacrylate, 1,4-butanediol dimethacrylate, 1,6-hexanediol dimethacrylate, 1,12-dodecanediol dimethacrylate, glycerol dimethacrylate and trimethylolpropane trimethacrylate.
  • Resin systems for the coating of metal surfaces are known. Intumescent coatings are described in particular in WO 2005/000975.
  • The coating preferably comprises one thermoplastic polymer resin in combination with low molecular mass monomers or oligomers having ethylenically unsaturated double bonds, in the form for example of alpha-beta ethylenically unsaturated carboxylic ester groups such as methacrylate or acrylate groups, for example. The notation (meth)acrylate here denotes not only methacrylate, such as methyl methacrylate, ethyl methacrylate, etc., for example, but also acrylate, such as methyl acrylate, ethyl acrylate, etc., for example, and also mixtures of both.
  • One thermoplastic polymer is preferably a (meth)acrylate resin in the form of homopolymer, copolymer and/or terpolymer. With particular preference a polymer component is a (meth)acrylate polymer. This polymer can be prepared via the polymerization of one or more methacrylate or acrylate monomers, preferably from the group of methyl (meth)acrylates, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate. Co-reagents may be styrene or vinyltoluenes. One particularly preferred thermoplastic polymer is a copolymer of butyl methacrylate and methyl methacrylate.
  • One ethylenically unsaturated monomer component comprises at least one methacrylate or acrylate functionality.
  • One ethylenically unsaturated monomer component is preferably selected from the group of methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate.
  • Another class of thermoplastic polymer resins comprises homopolymers, copolymers or terpolymers of vinyl monomers such as styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and/or vinyl esters. Co-reagents may be dienes, such as butadiene, for example.
  • The thermoplastic resins form 10%-60% by weight of the resin component of the coating mixture.
  • One polymeric component may comprise methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)-acrylate, isobutyl (meth)acrylate, tert-butyl (meth)-acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxy-propyl (meth)acrylate and/or 2-ethylhexyl (meth)-acrylate.
  • One polymeric component may also comprise a reaction product of one or more dienes with at least one styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and/or vinyl ester.
  • At least one of the liquid monomer components comprises methacrylate functionalities, with particular preference methacrylic esters. If desired it is also possible for an acrylate functionality to be present, preferably acrylic esters.
  • Moreover, the monomer component is monofunctional, so that the reaction product with an organic peroxide is thermoplastic and melts and flows up to the reaction temperature of the intumescent additives.
  • By way of example (meth)acrylic esters are selected from the group of methyl (meth)acrylates, ethyl (meth)-acrylates, n-butyl (meth)acrylates, isobutyl (meth)-acrylates, tert-butyl (meth) acrylates, 2-ethylhexyl (meth)acrylates and mixtures thereof. Methyl methacrylate and 2-ethylhexyl acrylate are particularly preferred.
  • The liquid monomer component forms 30%-60% by weight of the resin component of the coating mixture.
  • The resin component forms 10%-60% by weight, with particular preference 25%-50% by weight, of the coating mixture.
  • Initiators are used in order to cure the liquid coating. Use is made of AZO initiators or organic peroxides. Preferred initiators used are dialkyl peroxides, keto peroxides, peroxy esters, diacyl peroxides, hydroperoxides and/or peroxy ketals. The initiator is used in amounts of 0.5% to 5%, with particular preference 1%-4% with respect to the overall resin composition.
  • When using dibenzoyl peroxide as initiator it is preferred to add a tertiary amine in order to accelerate curing. Preferred tertiary amines are N,N-dimethylanilines and N,N-dialkyl-p-toluidines.
  • The fraction of the tertiary amines as a proportion of the overall resin mixture is 0.1%-4%, preferably 0.25%-3%.
  • Preferred azo initiators are 2,2-azobis(amidinopropane) dihydrochloride, 2,2-azobis(2-methylbutyronitrile), 2,2-azobis(2-methylpropanenitrile), 2,2-azobis(2,4-di-methylpentanenitrile), and mixtures thereof.
  • A substantial improvement in the adhesion properties of the intumescent coating on metal surfaces is achieved through the addition of acid (meth)acrylates or copolymerizable polyfunctionalized carboxylic acids. The acid (meth)acrylates are preferably selected from the group of dicarboxylic acids, particular preference being given to the use of β-CEA. Copolymerizable polyfunctionalized carboxylic acids that can be used include all known multiply functionalized carboxylic acids, selection taking place with particular preference from the group of itaconic acids, fumaric acids and maleic acids.
  • Beta-CEA is the Michael product of acrylic acid and is always a mixture of:
  • Figure US20100190886A1-20100729-C00001
      • beta-carboxyethyl acrylate
  • where n=1-20
  • The acid (meth)acrylates or copolymerizable polyfunctionalized carboxylic acids preferably form a part of the polymeric component of the resin.
  • These acid (meth)acrylates or copolymerizable polyfunctionalized carboxylic acids additionally have a good dispersing effect on the intumescent constituents used.
  • The object has also been achieved by a process for curing intumescent coatings comprising resin systems according to claim 1. The process of the invention is characterized in that at least one ethylenically unsaturated monomer component and at least one polymeric component comprising one acid (meth)acrylate or copolymerizable polyfunctionalized carboxylic acids and the customary intumescent auxiliaries and additives, are polymerized by means of free radical polymerization.
  • The intumescent coating comprises specific substances which when exposed to heat react with one another and form a foam for isolation. The coating is composed preferably of 3 components: an acid source, a carbon source and a gas source.
  • On exposure to heat, the resin component begins to melt. At higher temperatures the acid source is activated and is able to react with the other constituents of the coating. The acid source used is, for example, ammonium polyphosphates or polyphosphoric acids, which react with pentaerythritol (carbon source), for example, to form polyphosphoric ester. The breakdown of this ester leads to carbon compounds, which together with foaming agents such as melamine form the desired foam.
  • The intumescent coating ideally comprises at least one acid source such as ammonium polyphosphate, melamine phosphate, magnesium sulphate or boric acid, for example.
  • The intumescent coating mixture comprises a carbon source, such as pentaerythritol and dipentaerythritol and mixtures thereof, for example. Starch and expandable graphite are likewise suitable.
  • The intumescent coating mixture comprises a gas source, such as melamine, melamine phosphate, melamine borate, melamine-formaldehyde, melamine cyanurate, tris(hydroxyethyl)isocyanurate, ammonium polyphosphate or chlorinated paraffin, for example.
  • In addition there may be nucleating agents present.
  • These may be, for example, titanium dioxide, zinc oxide, aluminium oxide, silicon, silicates, heavy metal oxides such as cerium oxide, lanthanum oxide and zirconium oxide, mica or loam.
  • Further adjuvants (e.g. zinc borate, glass beads, fibre materials, etc.) may be present in the intumescent coating mixture.
  • The fraction of the intumescent components as a proportion of the coating mixture is 40%-85%, preferably 50%-75%.
  • Thixotropic adjuvants can be used in order to improve the rheology, in order to make thick coatings possible in one application step. They are added in amounts of 0%-2%, preferably 0.05%-1%, based on the total amount of the coating.
  • It is also possible for wetting adjuvants or dispersion adjuvants to be added.
  • Prior to the application of the coating to the metallic surface the organic peroxide is added. This initiates the free-radical reaction in the course of which the liquid coating cures. Typically the cure time is 30 minutes. It can be varied through the amount of initiator and accelerator.
  • The coating can be applied by means of spraying technology, brush, roller, spatula or dipping process. As an alternative it is also possible to use a multi-component spraying system.
  • The metal surface is typically cleaned before the coating is applied, in order to remove processing residues and the like. In some cases primers are applied as well.
  • It is also possible to apply a topcoat, for exposed metal surfaces, for example. The thickness however, should only be between 15 μm and 250 μm, in order not to inhibit the intumescent reaction.
  • The outstanding adhesion properties allow the resin system for intumescent coatings, in accordance with the invention, to be applied to other surfaces in need of an intumescent coating. Surfaces of wood, for example, can also be coated.
    • EXAMPLES Example 1
  • The resin system of the invention is processed using a
  • Graco Extreme Mix Plural Component Spray System. This airless spray system uses 2 pumps, which with an inlet pressure of 0.35 MPa spray the mixture through the nozzle at approximately 19.3 MPa. The nozzle size is approximately 525-675 μm in diameter.
  • Typically 300 μm to 2000 μm are applied per coating pass. In these experiments, 6 coating passes, each with a thickness of approximately 1000 μm, were applied to the substrate. The substrate coated was Swedish standard Sa 2½% construction steel.
  • Adhesion to the Steel
  • The adhesion of the coating to the construction steel was determined using a PAT (precision adhesion test equipment, hydraulic adhesion tester) instrument.
  • An adhesion of on average 6.9 MPa was measured.
  • This figure meets the requirements for a construction steel coating which can be used industrially.
    • Comparative Example
  • A conventional resin system is processed using a Graco Extreme Mix Plural Component Spray System. This airless spray system uses 2 pumps, which with an inlet pressure of 0.35 MPa spray the mixture through the nozzle at approximately 19.3 MPa. The nozzle size is approximately 525-675 μm in diameter.
  • Typically 300 μm to 2000 μm are applied per coating pass. In these experiments, 6 coating passes, each with a thickness of approximately 1000 μm, were applied to the substrate. The substrate coated was Swedish standard Sa 2½ construction steel.
  • Adhesion to the Steel
  • The adhesion of the coating to the construction steel was determined using a PAT (precision adhesion test equipment, hydraulic adhesion tester) instrument.
  • An adhesion of on average 1.38 MPa was measured.
  • This figure does not meet the requirements for a construction steel coating which can be used industrially.

Claims (15)

1. Resin system for an intumescent coating comprising at least one ethylenically unsaturated monomer component, characterized in that there is at least one polymeric component comprising an acid (meth)acrylate or copolymerizable polyfunctionalized carboxylic acids present.
2. Resin system for an intumescent coating according to claim 1, characterized in that the acid (meth)acrylate is selected from the group of dicarboxylic acids.
3. Resin system for an intumescent coating according to claim 2, characterized in that the acid (meth)acrylate is selected from the group of beta-CEA.
4. Resin system for an intumescent coating according to claim 1, characterized in that the copolymerizable polyfunctionalized carboxylic acids are selected from the group of itaconic acids, fumaric acids or maleic acids.
5. Resin system for an intumescent coating according to claim 1, characterized in that one polymeric component is selected from the group of thermoplastic resins.
6. Resin system for an intumescent coating according to claim 5, characterized in that one polymeric component is selected from the group of homopolymers, copolymers and/or terpolymers of a (meth)acrylic resin.
7. Resin system for an intumescent coating according to claim 1, characterized in that one polymeric component comprises a (meth)acrylate copolymer.
8. Resin system for an intumescent coating according to claim 1, characterized in that one polymeric component comprises one methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth) acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate.
9. Resin system for an intumescent coating according to claim 1, characterized in that one polymeric component comprises a reaction product of one or more dienes with at least one of styrene, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride and/or vinyl ester.
10. Resin system for an intumescent coating according to claim 1, characterized in that one ethylenically unsaturated monomer component comprises one methacrylate or acrylate functionality.
11. Resin system for an intumescent coating according to claim 9, characterized in that one ethylenically unsaturated monomer component comprises methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, 2 hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate and/or 2-ethylhexyl (meth)acrylate.
12. Process for curing an intumescent coating comprising a resin system according to claim 1, characterized in that at least one ethylenically unsaturated monomer component and at least one polymeric component comprising an acid (meth)acrylate or copolymerizable, polyfunctionalized carboxylic acids and the typical intumescent auxiliaries and additives are polymerized by means of free radical polymerization.
13. Process for curing an intumescent coating according to claim 11, characterized in that auxiliaries and additives used are initiators, preferably organic peroxides.
14. Process for curing an intumescent coating according to claim 12, characterized in that initiators used are dialkyl peroxides, keto peroxides, peroxy esters, diacyl peroxides, hydroperoxides and/or peroxy ketals.
15. Use of the intumescent coating according to claim 1 for coating metal surfaces and wood surfaces.
US12/669,573 2007-07-20 2008-06-25 Resin system for intumescent coating with enhanced metal adhesion Abandoned US20100190886A1 (en)

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US9228093B2 (en) 2013-10-18 2016-01-05 Weyerhaeuser Nr Company Colored water-repellant and crocking-resistant compositions
US9447227B2 (en) 2013-10-03 2016-09-20 Sabic Global Technologies B.V. Flexible polyurethane foam and associated method and article
US9493621B2 (en) 2013-07-23 2016-11-15 Sabic Global Technologies B.V. Rigid foam and associated article and method
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US11459417B2 (en) 2018-05-07 2022-10-04 Zeon Corporation Block copolymer composition including ionic group, and film
US11466150B2 (en) 2017-05-11 2022-10-11 Zeon Corporation Block copolymer composition obtained by modification treatment, method for producing same, modified block copolymer composition used for same, and method for producing said modified block copolymer composition
CN115279806A (en) * 2020-03-11 2022-11-01 罗姆化学有限责任公司 Improved resin system for intumescent coatings

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US20210108023A1 (en) 2019-10-15 2021-04-15 Swimc Llc Flexible coating composition
EP3904407A1 (en) 2020-04-28 2021-11-03 Röhm GmbH Stabilizers for particularly storage-stable (meth) acrylate-based reactive resins with acidic adhesion promoters
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US11459417B2 (en) 2018-05-07 2022-10-04 Zeon Corporation Block copolymer composition including ionic group, and film
WO2020077334A1 (en) * 2018-10-12 2020-04-16 Case Western Reserve University Intumescent polyacrylic acid compositions
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CN115279806A (en) * 2020-03-11 2022-11-01 罗姆化学有限责任公司 Improved resin system for intumescent coatings

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KR20150117709A (en) 2015-10-20
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KR20100050458A (en) 2010-05-13
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US8921456B2 (en) 2014-12-30
CA2693499C (en) 2016-02-09
CA2693499A1 (en) 2009-01-29
AU2008280344B2 (en) 2014-02-13
US20120164462A1 (en) 2012-06-28
AU2008280344A1 (en) 2009-01-29
TR201909505T4 (en) 2019-07-22

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