Classifications

• • 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
• • 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
  • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/20—Mica; Vermiculite
  • C04B14/206—Mica or vermiculite modified by cation-exchange; chemically exfoliated vermiculate
  • C04B14/208—Mica or vermiculite modified by cation-exchange; chemically exfoliated vermiculate delaminated mica or vermiculite platelets
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/22—Expanded, porous or hollow particles
  • C08K7/24—Expanded, porous or hollow particles inorganic
  • C08K7/26—Silicon- containing compounds
• • 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
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/60—Additives non-macromolecular
  • C09D7/61—Additives non-macromolecular inorganic
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/02—Inorganic materials

Definitions

• the invention concerns a fire resistant or fire retardant paint that can be applied by spraying the paint onto a surface.
• the paint is a stable dispersed suspension of a mixture of chemically exfoliated vermiculite and thermally exfoliated vermiculite.
• the paint is capable of providing performance which significantly exceeds that required for Class "O" fire resistance according to BS476 Pt 6 & 7 or its equivalent Euro BSEN 11925 BSEN 13823 test.
• the fire resistant paint may be applied to flammable surfaces in high risk areas such as below decks in ships or submarines or other high risk areas in buildings or other structures where the spread of fire would be catastrophic, for example as cruise liners, underground railway systems and airports
• the fire resistant paint may be applied during the construction process but may also be applied to existing surfaces to provide protection against fire for example in an existing commercial environment or in a heritage environment where the protection of carved wood is required.
• the invention relates to the use of an aqueous suspension of fine expanded vermiculite particles that have been formulated such that the suspension can be applied by spraying it onto a surface to vastly improve its fire protection.
• the suspension is preferably formulated such that it does not settle within the container in which it is supplied, such that its adhesion to the surface being coated is good and such that running on vertical surfaces is minimised.
• the base material for the aqueous suspension of fire resistant paint is Vermiculite which is a naturally occurring mineral of chemical formula
• Vermiculite may be expanded by heat or chemical treatment to form exfoliated (expanded) vermiculite.
• This fire resistant paint may have a solids content of between 5 % and 35 % of exfoliated vermiculite more preferably between 15% and 25 % of exfoliated vermiculite such as about 20 %.
• Exfoliated vermiculite particles may be suspended in a stable aqueous dispersion.
• Aqueous suspensions of expanded vermiculite have been used for fireproofing flexible materials such as paper and cloth.
• US 6,309,740 identifies methods for manufacturing aqueous suspensions of expanded vermiculite and discloses the use of a spray coating of an aqueous suspension of chemically exfoliated vermiculite as a secondary layer to a primary cementitious fireproofing composition coating.
• the present invention relates to the use of an aqueous suspension of fine expanded vermiculite as spray paint for surfaces of substrates that need to have their fire resistance enhanced.
• the vermiculite content in the suspension is preferably formulated for spray application and to minimise running when applied to vertical surfaces.
• the vermiculite is preferably very fine with a particle size between one nanometre to 1000 micrometres and preferably not greater than 300 micrometres.
• the D90 particle size dispersion is preferably in the range 100 micrometres to 300 micrometres more preferably 140 micrometres to 250 micrometres especially 160 micrometres to 200 micrometres.
• the vermiculite solids content is a mixture of chemically exfoliated vermiculite and thermally exfoliated vermiculite.
• the chemical exfoliated vermiculite is between 75% and 99% by weight of the total vermiculite content more preferably between 88 % and 96 % such as 95 % and the thermally exfoliated vermiculite content is between 25% and 1 % by weight of the total vermiculite content more preferably between 12 % and 4 % such as 5 %.
• Suspensions of mixtures of chemically exfoliated and mechanically exfoliated vermiculite with viscosity in the range of 5,500 to 10,000 cps when measured on a Brookfield test machine, number 6 bob at 20 rpm are preferred for spray application as a fire resistant or fire retardant paint with good adhesion and non-run properties.
• the viscosity so measured is not less than 8,000, more preferably not less than 8,400 such as at least 8,500 cps.
• the viscosity is not more than 9,000 cps, preferably not more than 8,700 cps such as at most 8,600 cps.
• the suspension may additionally include other additives such as anti settling and flocculating agents conventionally used in spray paints in order to enhance performance provided that they do not interfere with the ability of the vermiculite to remain in suspension over an extended period or damage its fire resistant characteristics.
• the vermiculite will remain in suspension if left undisturbed for a period of at least 6 months at room temperature such as at between 5 to 35 degrees centigrade, for example at 20 degrees centigrade, more preferably at least 12 months especially 24 months or more.
• the aqueous dispersed vermiculite spray paint achieves its fire resistant and fire retardant properties in four ways:
• the dried aqueous vermiculite dispersion insulates the surface it has been applied to thereby preventing it from reaching its self ignition temperature when it is exposed to heat.
• the dried aqueous vermiculite dispersion provides an oxygen resistant barrier such that the flammable materiel that has been coated with the fire resistant paint does not combust even if it does reach ignition temperature as it is starved of oxygen.
• the dried aqueous vermiculite dispersion is inert and will withstand
• the vermiculite has a propensity to self heal any opening in its surface such that a barrier for oxygen penetration is maintained, this is by nature of the platelet structure of the vermiculite particles that joint together as can be seen under an electron microscope in the cold condition.
• Figure 1 is an illustrative size distribution chart for Vermiculite Dispersion DM651 developed by Dupre Minerals Limited .
• DM651 was developed by Dupre Minerals Limited for the purposes of spray application with a mixture of chemically expanded vermiculite and thermally expanded vermiculite in the ratio 95% to 5 % in controlled particle size ranges and with these solids constituting 20 % by weight of an aqueous solution .
• the vermiculite is capable of being retained in suspension in such dispersions for extended periods such as for months or a year or two years or more.
• DM651 from Dupre Minerals Limited has a size distribution for illustrative purposes set out in Figure 1. The particles range from nanometre sizes to 1000 micrometres with the majority of the vermiculite being around 300 micrometres in size.
• the particle size distribution should be such that the vermiculite may be maintained in suspension over an extended period, will provide a suitable spray when administered from conventional spray equipment be it airless or with air, will maintain a good coating ability when sprayed and will provide a good thermal insulation and form oxygen barrier properties when sprayed.
• Vermiculite particle sizes in a range of up to 2000 micrometres preferably less than 1000 micrometres and more preferably 300 micrometres or less are suitable for this purpose.
• the vermiculite particles have a D90 of between 50 micrometres and 300 micrometres, preferably between 100 micrometres and 250 micrometres, more preferably between 150 micrometres and 200 micrometres.
• Vermiculite may be present in a suitable suspension at between 1% and 40% by weight, preferably 10 to 30% and more preferably 15% to 25% especially about 20 %.
• aqueous suspension of vermiculite with no additional additives and especially a suspension in deionised or distilled water provides an excellent non-toxic spray medium
• the suspension may additionally include other additives such as anti-settling agents and flocculating agents conventionally used in spray paint systems to enhance performance and additives to enhance the stability of the suspension.
• the additives should preferably not adversely interfere with the ability of the vermiculite to remain in suspension over an extended period and preferably should not interfere with the ability of the suspension when sprayed to form a protective fire resistant inert and thermal insulating coating.
• the following examples illustrate the benefits of vermiculite suspension as a fire barrier material capable of being sprayed.
• Example 1 Warrington Blue board test Blue Board BS 476 Part 6 and 7 fire test at Exova Warrington.
• Blue Boards are sprayed using Industrial Airless Spray Gun, 429 nozzles, with 3 passes of the spray gun using DM651 vermiculite dispersion. Samples are then dried in ambient temperature until weight loss stops before testing Testing - BS 476 Part 6
• the blue board samples are placed into a frame and bolted into the fully enclosed test rig. Flame is applied to the test piece via a burner bar at the bottom of the rig to ignite the test sample before a radiant heater is turned on.
• the temperature increase is measured at set intervals and recorded.
• a calibration temperature is deducted from the measured specimen
• the coated blue board is suspended in a metal frame held at right angles to a large radiant heater. For the first minute and a half a gas flame is applied to the bottom left hand corner of the test piece in an attempt to light it via a gas burner tube at the bottom left corner of the test piece. The radiant heater is turned on and the distance the flame travels after 10 minutes duration is recorded.
• the 95% chemically and 5% mechanically exfoliated 20% by weight solids finely divided vermiculite dispersion Dupre DM651 was applied to a wooden board in a vertical orientation by spraying using Industrial Airless Spray Gun, 429 nozzles. The result was excellent adhesion with little to no tendency to run. The sprayed material dried to form a regular and intact coating.
• mechanically exfoliated vermiculite therefore permits the production of a suspension which can successfully be applied by spraying to a substrate and which adheres without running on a vertical or inclined or irregularly formed surface.
• the viscosity of the Dupre DM651 suspension as measured on a Brookfield test machine, number 6 bob at 20 rpm was 8600 cps. This may be contrasted with Dupre DM338S a comparable suspension of chemically exfoliated vermiculite with a similar particle size profile with a viscosity determined on the same basis of 1,560 cps.
• Suspensions of mixtures of chemically exfoliated and mechanically exfoliated vermiculite with viscosity as measured on a Brookfield test machine, number 6 bob at 20 rpm in the range of 5,500 to 10,000 cps are preferred for spray application as a fire resistant or fire retardant paint with good adhesion and non-run properties.
• the viscosity of the paint as measured on a Brookfield test machine number 6 bob at 20 rpm is not less than 8,000, more preferably not less than 8,400 such as at least 8,500.
• the viscosity as measured on a Brookfield test machine number 6 bob at 20 rpm is not more than 9,000 cps, preferably not more than 8,700 cps such as at most 8,600 cps.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Inorganic Chemistry (AREA)
• Ceramic Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Civil Engineering (AREA)
• Health & Medical Sciences (AREA)
• Structural Engineering (AREA)
• Paints Or Removers (AREA)
• Fireproofing Substances (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Building Environments (AREA)

Priority Applications (12)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

Country Status (14)

Cited By (2)

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Citations (5)

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• 2012
  • 2012-07-13 GB GB1212530.8A patent/GB2503937A/en not_active Withdrawn
• 2013
  • 2013-07-12 EP EP13739272.6A patent/EP2872571B1/en not_active Not-in-force
  • 2013-07-12 KR KR1020157003025A patent/KR20150036384A/ko not_active Withdrawn
  • 2013-07-12 BR BR112015000523A patent/BR112015000523A2/pt not_active Application Discontinuation
  • 2013-07-12 US US14/413,208 patent/US10266706B2/en active Active
  • 2013-07-12 NO NO13739272A patent/NO2872571T3/no unknown
  • 2013-07-12 PT PT137392726T patent/PT2872571T/pt unknown
  • 2013-07-12 CA CA2878888A patent/CA2878888A1/en not_active Abandoned
  • 2013-07-12 ES ES13739272.6T patent/ES2654648T3/es active Active
  • 2013-07-12 CN CN201380037090.5A patent/CN104583340B/zh not_active Expired - Fee Related
  • 2013-07-12 AU AU2013288420A patent/AU2013288420B2/en not_active Ceased
  • 2013-07-12 RU RU2015103120A patent/RU2642793C2/ru active
  • 2013-07-12 JP JP2015521068A patent/JP6307502B2/ja not_active Expired - Fee Related
  • 2013-07-12 WO PCT/GB2013/051864 patent/WO2014009748A1/en not_active Ceased

Patent Citations (5)

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