WO2025193669A1

WO2025193669A1 - Intumescent coating composition and methods of making and using the same

Info

Publication number: WO2025193669A1
Application number: PCT/US2025/019322
Authority: WO
Inventors: Simon Butterfield; Ruisong Xu; Anthony J. Tye; Jr. Raymond J. Weinert
Original assignee: Swimc LLC
Current assignee: Swimc LLC
Priority date: 2024-03-12
Filing date: 2025-03-11
Publication date: 2025-09-18
Anticipated expiration: 2026-09-12

Abstract

An intumescent coating composition includes a resin system including a reaction product of: an epoxy component and a mono-functional carboxylic acid; a monomer mixture that includes at least one ethylenically unsaturated monomer; and an intumescent component, wherein the composition is curable by free radical polymerization. A method of making the intumescent coating composition includes mixing the epoxy component and the mono-functional carboxylic acid to form a reaction product through a ring opening reaction of the epoxy component; and mixing an intumescent component with the reaction product and a monomer mixture. A method of coating a substrate with the intumescent coating includes mixing the liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition; applying the activated coating composition onto the substrate; and allowing the activated coating composition to cure under ambient conditions into a solid state to form the intumescent coating.

Description

INTUMESCENT COATING COMPOSITION AND METHODS OF MAKING AND

USING THE SAME

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63/564,157, filed March 12, 2024 and U.S. Provisional Application No. 63/674,521, filed July 23, 2024, the disclosures of which are incorporated by reference herein their entireties.

Field

[0002] The present disclosure relates to intumescent coating compositions and intumescent coatings made from the same. The present disclosure further relates to methods of making and using intumescent coating compositions.

Introduction

[0003] Buildings and structures may be protected from the damaging effects of fire by the use of a variety of fire protection systems, including mineral insulants, cementitious sprays, intumescent coatings, free-standing intumescent sheets, and the like. An intumescent material expands when exposed to heat and can be used to insulate materials and structures from heat and to slow down the spread of fire by blocking openings through which fire could spread. During a fire, an intumescent coating undergoes a series of reactions to produce an insulating char that slow down heat transfer to the underlying structure. This delays the time at which the structure loses its load-bearing strength. Some intumescent materials produce a light char as a result of heating of the components of the intumescent material, such as carbon-containing binders. Some intumescent materials, such as those containing sodium silicate or graphite, may produce a hard char. Intumescent material may further include flame retardant agents or compounds, such as hydrates, that have a cooling effect upon heating and decomposing.

[0004] Intumescent coatings may be used on various different materials, including metals such as steel, aluminum, and other metals, concrete, wood, plastics, and combinations thereof. [0005] Liquid intumescent coating compositions may be used as a paint to cover surfaces. Many such existing liquid intumescent coating compositions result in a thick application and may suffer from defects in the appearance of the coating, such as ripples or other uneven texture.

[0006] Further improvements to liquid intumescent coating compositions are desired.

Summary

[0007] An intumescent coating composition includes a resin system that includes a reaction product of: an epoxy component and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture that includes at least one ethylenically unsaturated monomer; and an intumescent component, wherein the composition is curable by free radical polymerization. The epoxy component and the mono-functional carboxylic acid may be dissolvable in the monomer mixture. The reaction product may be dissolved in the monomer mixture. The epoxy component may include an epoxy resin that includes two or more epoxide groups. The epoxy component may include an epoxy resin that is solid at a temperature of 20 °C. The intumescent coating composition may be free of solvents other than the monomer mixture. The monomer mixture may constitute from 30 % to 90 % of the resin system by weight. The reaction product may constitute from 2 % to 60 % of the intumescent coating composition by weight.

[0008] The intumescent coating composition may be a two-part composition, where a first part includes the reaction product, the monomer mixture, and the intumescent component, and where a second part includes a peroxide initiator. The first part may further include an amine accelerator. In some embodiments, the intumescent coating composition may be provided as a three-part composition.

[0009] The intumescent component may include an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

[0010] A method of making the intumescent coating composition includes mixing the epoxy component and the mono-functional carboxylic acid to form a reaction product through a ring opening reaction of the epoxy component; and preparing the coating composition by mixing an intumescent component with the reaction product and a monomer mixture that includes at least one ethylenically unsaturated monomer. The method may include mixing an epoxide-ring- opening catalyst with the epoxy component and the mono-functional carboxylic acid.

[0011] A method of coating a substrate with the intumescent coating includes mixing the liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition; applying the activated coating composition onto the substrate; and allowing the activated coating composition to cure under ambient conditions into a solid state to form the intumescent coating. The liquid intumescent coating composition may be cured via free radical polymerization. The liquid intumescent coating composition may be cured at ambient temperature, exposed to air. The initiator may include an organic peroxide. The activated coating composition may be cured in 60 minutes or less at a temperature of 25 °C or less. Less than 5 % by weight of volatile components may be lost from the coating composition by evaporation during the curing. The cured intumescent coating may have a Shore D hardness of 45 to 90 measured 24 hours after application.

[0012] A kit for applying an intumescent coating to a substrate may include a first part that includes a resin system, and a second part that includes a peroxide initiator and an amine accelerator. The resin system includes a reaction product of an epoxy component and a monofunctional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture includes at least one ethylenically unsaturated monomer; and an intumescent component.

Brief Description of Drawings

[0013] FIG. 1 is a TGA graph of a sample made in Example 14 according to an embodiment.

[0014] FIGS. 2A-2D are TGA graphs of samples made in Example 15 according to an embodiment.

Definitions

[0015] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure. [0016] Unless otherwise indicated, the terms “polymer” and “polymeric material” include, but are not limited to, organic homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.

[0017] The term “organic group” is used here to mean a hydrocarbon group (with optional elements other than carbon and hydrogen, such as oxygen, nitrogen, sulfur, and silicon) that is classified as an aliphatic group, cyclic group, or combination of aliphatic and cyclic groups (e.g., alkaryl and aralkyl groups). The term “aliphatic group” means a saturated or unsaturated linear or branched hydrocarbon group. This term is used to encompass alkyl, alkenyl, and alkynyl groups, for example. The term “alkyl group” means a saturated linear or branched hydrocarbon group including, for example, methyl, ethyl, isopropyl, t-butyl, heptyl, dodecyl, octadecyl, amyl, 2-ethylhexyl, and the like. Unless otherwise indicated, the alkyl groups typically contain from 1 to 30 carbon atoms. In some embodiments, the alkyl groups contain 4 to 30 carbon atoms, 6 to 30 carbon atoms, or 6 to 26 carbon atoms. The term “alkenyl group” means an unsaturated, linear or branched hydrocarbon group with one or more carbon-carbon double bonds, such as a vinyl group. The term “alkynyl group” means an unsaturated, linear or branched hydrocarbon group with one or more carbon-carbon triple bonds. The term “cyclic group” means a closed ring hydrocarbon group that is classified as an alicyclic group, aromatic group, or heterocyclic group. The term “alicyclic group” means a cyclic hydrocarbon group having properties resembling those of aliphatic groups. The term “aromatic group” or “aryl group” means a mono- or polynuclear aromatic hydrocarbon group. The term “heterocyclic group” means a closed ring hydrocarbon in which one or more of the atoms in the ring is an element other than carbon (e.g., nitrogen, oxygen, sulfur, etc.). A group that may be the same or different is referred to as being “independently” something.

[0018] The term “alkylated” is used in this disclosure to describe compounds that are reacted to replace a hydrogen atom or a negative charge of the compound with an alkyl group, such that the alkyl group is covalently bonded to the compound. [0019] The term “substantially” as used here has the same meaning as “significantly,” and can be understood to modify the term that follows by at least about 90 %, at least about 95 %, or at least about 98 %. The term “substantially free” of a particular compound means that the compositions of the present invention contain less than 1,000 parts per million (ppm) of the recited compound. In the context of the aforementioned phrases, the compositions of the present invention contain less than the aforementioned amount of the compound whether the compound itself is present in unreacted form or has been reacted with one or more other materials.

[0020] The term “not substantially” as used here has the same meaning as “not significantly,” and can be understood to have the inverse meaning of “substantially,” i.e., modifying the term that follows by not more than 25 %, not more than 10 %, not more than 5 %, or not more than 2 %.

[0021] The term “about” is used here in conjunction with numeric values to include normal variations in measurements as expected by persons skilled in the art, and is understood to have the same meaning as “approximately” and to cover a typical margin of error, such as ±5 % of the stated value.

[0022] Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration.

[0023] The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of’ and “comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0024] As used here, the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise. The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0025] The recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.

[0026] As used here, “have,” “having,” “include,” “including,” “comprise,” “comprising,” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising” and the like. As used herein, “consisting essentially of,” as it relates to a composition, product, method, or the like, means that the components of the composition, product, method, or the like are limited to the enumerated components and any other components that do not materially affect the basic and novel characteristic(s) of the composition, product, method, or the like.

[0027] The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0028] Any direction referred to here, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Devices or systems as described herein may be used in a number of directions and orientations.

Detailed Description

[0029] The present disclosure relates to intumescent coating compositions and intumescent coatings made from the same. The present disclosure further relates to methods of making and using intumescent coating compositions.

[0030] It would be desirable to provide a solvent-free intumescent coating composition capable of protecting structures during a fire. It would be desirable to provide an intumescent coating composition that can be applied as a thinner coating compared to existing compositions. It would be further desirable to provide an intumescent coating composition that can be polymerized via free radical polymerization in air.

[0031] The intumescent coating composition may be applied to a substrate and cured to form an intumescent coating. The term intumescent coating composition is used here to refer to the liquid composition prior to curing, and the term intumescent coating is used to refer to the coating after curing. The intumescent coating composition may be provided in two or more parts that may be combined prior to application. [0032] According to an embodiment, the intumescent coating composition of the present disclosure includes an adduct or includes reactants that create the adduct that, when applied to a substrate, migrates to the surface of the coating, creating a passivating layer, below which monomers react via free-radical polymerization. The passivating layer allows the free-radical polymerization to progress without oxygen inhibition. The intumescent coating composition of the present disclosure creates an intumescent coating that is thinner than coatings formed from existing intumescent coating compositions. The intumescent coating composition of the present disclosure creates an intumescent coating with equivalent or improved fire test performance compared to existing products. The intumescent coating composition of the present disclosure creates an intumescent coating with equivalent or improved resistance to deleterious effects of water exposure compared to existing products.

[0033] The intumescent coating composition generally includes an intumescent component and a resin system. The resin system includes a monomer mixture, an epoxy component, and a monofunctional carboxylic acid, and/or a reaction product of the epoxy component and the monofunctional carboxylic acid. The monomers of the liquid intumescent coating composition may function as a reactive diluent. That is, other components, including the epoxy component, the mono-functional carboxylic acid, and/or the reaction product of the epoxy component and the mono-functional carboxylic acid are soluble in the monomers. The liquid intumescent coating composition may be free or substantially free of solvents other than the monomers. That is, the liquid intumescent coating composition may be free or substantially free of solvents that do not polymerize and become part of the coating. The liquid intumescent coating composition may be free or substantially free of solvents that would volatilize during curing. The liquid intumescent coating composition may be referred to as being solvent-free. The term “solvent-free” as used here refers to the absence of solvents other than the reactive diluent.

[0034] The intumescent coating composition and intumescent coating include one or more intumescent components. Examples of intumescent components include an acid source, a carbon source, a gas source, and combinations thereof. The intumescent coating composition and intumescent coating may include at least one of each of an acid source, a carbon source, and a gas source. [0035] The gas source may provide an expansion gas upon thermal decomposition. Such gas sources are sometimes referred to as “spumifics.” The gas causes the char produced by the intumescent coating to swell and to produce a multicellular foam that insulates the underlying structure. The foam may have a volume that is multiple times the volume of the coating prior to being exposed to heat. For example, the volume after exposure to heat (e.g., the expanded volume) of the coating (e.g., foam) may be 2 times or more, 5 times or more, 8 times or more, 10 times or more, or 20 times or more the volume of the coating prior to exposure to heat.

[0036] Examples of suitable gas sources include nitrogen-containing materials, carbon dioxide releasing materials, and water vapor releasing materials. The intumescent coating composition may include any one or any combination of two or more of the following suitable gas sources. Suitable nitrogen-containing materials include, for example, melamine, phosphoric acid salts (e.g., ammonium polyphosphate, ammonium polyphosphate, melamine phosphate, magnesium sulphate, boric acid and amine sulphates, and combinations of two or more thereof), guanidine, methylolated melamine, hexamethoxymethyl melamine, urea, dimethylurea, melamine pyrophosphate, dicyandiamide, guanylurea phosphate, glycine, and the like, and combinations of two or more thereof. In some embodiments, the gas source is or includes melamine. In some embodiments, the gas source is or includes a salt of phosphoric acid. In some embodiments, the gas source includes melamine and a salt of phosphoric acid. Suitable carbon dioxide releasing materials include, for example, alkaline earth metal carbonates, such as calcium carbonate and magnesium carbonate. Suitable water vapor releasing materials include, for example, calcium hydroxide, magnesium dihydroxide, and aluminum trihydroxide, and combinations of two or more thereof. Another compound that may be used as an intumescent material is boric acid and its derivatives.

[0037] The intumescent coating composition and intumescent coating may include a carbon source. The carbon source forms a carbonaceous char during a fire. Preferably the intumescent coating forms a char layer during a fire and the char layer adheres to the underlying substrate without cracking.

[0038] Examples of suitable carbon sources include polyhydroxy compounds such as pentaerythritol, dipentaerythritol, glycerol, oligomeric glycerol, xylitol, mannitol, sorbitol, and polymers such as polyamides, polycarbonates, polyurethanes, and combinations of two or more thereof.

[0039] The intumescent coating composition and intumescent coating may include an acid source. Examples of suitable acid sources include ammonium phosphate, ammonium polyphosphate, diammonium diphosphate, diammonium pentaborate, phosphoric acid generating materials, boric acid, metal or organic borates, and combinations of two or more thereof.

[0040] The one or more intumescent components may be present in the intumescent coating composition at a concentration that results in the desired intumescent performance. The amount may vary based on the specific intumescent components used. In some embodiments, the one or more intumescent components may be present in the intumescent coating composition at a concentration of 1 wt-% or higher, 5 wt-% or higher, 10 wt-% or higher, 15 wt-% or higher, 20 wt-% or higher, 25 wt-% or higher, 30 wt-% or higher, 35 wt-% or higher, 40 wt-% or higher, 45 wt-% or higher, or 50 wt-% or higher. In some embodiments, the one or more intumescent components may be present in the intumescent coating composition at a concentration of 60 wt- % or lower, 50 wt-% or lower, 40 wt-% or lower, 35 wt-% or lower, 30 wt-% or lower, 25 wt-% or lower, 20 wt-% or lower, 15 wt-% or lower, 10 wt-% or lower, or 5 wt-% or lower. In some embodiments, the one or more intumescent components may be present in the intumescent coating composition at a concentration of 1 wt-% to 60 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 30 wt-% .

[0041] The intumescent coating composition includes a resin system that includes a monomer mixture, an epoxy component, and a mono-functional carboxylic acid and/or a reaction product of the epoxy component and the mono-functional carboxylic acid. According to an embodiment, the epoxy component and the mono-functional carboxylic acid are dissolvable in the monomer mixture. The epoxy component and the mono-functional carboxylic acid react to form a reaction product. The reaction product of the epoxy component and the mono-functional carboxylic acid may also be dissolvable and/or dissolved in the monomer mixture.

[0042] According to an embodiment, when the intumescent coating composition is applied to a substrate, the reaction product (e.g., adduct) of the epoxy component and the mono-functional carboxylic acid migrates to the surface of the coating, creating a passivating layer. The monomers can react below the passivating layer via free-radical polymerization. [0043] The epoxy component may include an epoxy resin with two or more epoxide groups. The epoxy component may include an epoxy resin that is solid at ambient temperature. For example, the epoxy component may include an epoxy resin that is solid at a temperature below 30 °C, 25 °C, or at about 20 °C. The epoxy component may include an epoxy resin having a glass transition temperature 20 °C or higher, 25 °C or higher, or 30 °C or higher. The epoxy component may include an epoxy resin having a molecular weight of 500 or greater, 800 or greater, 1000 or greater, 1500 or greater, 1800 or greater, or 2000 or greater. The molecular weight of the epoxy resin may be 5000 or lower, 4600 or lower, 4000 or lower, 3500 or lower, 3000 or lower, or 2500 or lower. The molecular weight of the epoxy resin may be in a range from 500 to 5000, from 800 to 4600, from 1000 to 4000, from 1500 to 3000, or from 1800 to 2500.

[0044] Examples of suitable epoxy resins include butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3 -propanediol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6- hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, and combinations of two or more thereof. In some embodiments the epoxy component includes an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof. In some embodiments the epoxy component includes a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A. [0045] The epoxy component may be present in the intumescent coating composition at a concentration that results in the desired coating performance. The amount may vary based on the specific epoxy resins used. The amount may also vary based on the amount of carboxylic acid used that is intended to react with the epoxy component. The amount may further vary based on the amount of resins in the composition as a whole. The intumescent coating composition may be provided as a two-part composition. The concentration of the epoxy component may be given as the concentration in the first part which includes the resin system. In some embodiments, the epoxy component may be present in the intumescent coating composition at a concentration of 2 wt-% or higher, 5 wt-% or higher, 10 wt-% or higher, 15 wt-% or higher, 20 wt-% or higher, 25 wt-% or higher, 30 wt-% or higher, 35 wt-% or higher, 40 wt-% or higher, 45 wt-% or higher, or 50 wt-% or higher. In some embodiments, the epoxy component may be present in the intumescent coating composition at a concentration of 60 wt-% or lower, 50 wt-% or lower, 40 wt-% or lower, 35 wt-% or lower, 30 wt-% or lower, 25 wt-% or lower, 20 wt-% or lower, 15 wt- % or lower, 10 wt-% or lower, or 5 wt-% or lower. In some embodiments, the epoxy component may be present in the intumescent coating composition at a concentration of 2 wt-% to 60 wt-%,

5 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 30 wt-%.

[0046] The mono-functional carboxylic acid may have a chain length of 4 or more, 6 or more, 8 or more, or 10 or more carbons. The mono-functional carboxylic acid may have a chain length of 36 or fewer, 32 or fewer, 30 or fewer, 28 or fewer, 26 or fewer, 24 or fewer, 22 or fewer, or 20 or fewer carbons. The mono-functional carboxylic acid may have a chain length of 4 to 36 carbons,

6 to 30 carbons, or 8 to 22 carbons.

[0047] Any suitable mono-functional carboxylic acid may be used. According to an embodiment, the mono-functional carboxylic acid is dissolvable in the monomer mixture. The mono-functional carboxylic acid may be straight, branched, or cyclic. The mono-functional carboxylic acid may be a saturated carboxylic acid. The mono-functional carboxylic acid may include substitutions along the carbon chain, such as substituted nitrogen, sulfur, or oxygen atoms. The mono-functional carboxylic acid may include additional functional groups, as long as the additional functional groups do not interfere with the reaction between the epoxy component and the mono-functional carboxylic acid. The mono-functional carboxylic acid generally has a formula R-COOH, where R is an organic group. Exemplary mono-functional carboxylic acids include butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)3COOH), hexanoic (caproic) acid (CHs(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)eCOOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)8COOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)IOCOOH), tridecanoic acid (CH3(CH2)nCOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ISCOOH), octadecadienoic (linoleic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), etc.

[0048] The mono-functional carboxylic acid may be present in the intumescent coating composition at a concentration that results in the desired coating performance. The amount may vary based on the mono-functional carboxylic acid used. The amount may vary based on the amount of epoxy component used that is intended to react with the mono-functional carboxylic acid. The amount may further vary based on the amount of resins in the composition as a whole. The amount of mono-functional carboxylic acid on a weight basis will vary depending on the molecular weight of the acid. The intumescent coating composition may be provided as a two- part composition. The concentration of the mono-functional carboxylic acid may be given as the concentration in the first part which includes the resin system. In some embodiments, the monofunctional carboxylic acid may be present in the intumescent coating composition at a concentration of 1 wt-% or higher, 2 wt-% or higher, 3 wt-% or higher, 4 wt-% or higher, 5 wt-% or higher, 6 wt-% or higher, 7 wt-% or higher, 8 wt-% or higher, or 9 wt-% or higher. In some embodiments, the mono-functional carboxylic acid may be present in the intumescent coating composition at a concentration of 10 wt-% or lower, 9 wt-% or lower, 8 wt-% or lower, 7 wt-% or lower, 6 wt-% or lower, 5 wt-% or lower, 4 wt-% or lower, 3 wt-% or lower, or 2 wt-% or lower. In some embodiments, the mono-functional carboxylic acid may be present in the intumescent coating composition at a concentration of 1 wt-% to 10 wt-%, 2 wt-% to 9 wt-%, 3 wt-% to 8 wt-%, 4 wt-% to 7 wt-%, or 5 wt-% to 6 wt-%.

[0049] The epoxy component reacts with the mono-functional carboxylic acid to form a long chain pendant ester. The reaction may be accelerated by using a catalyst that opens the epoxide ring(s) of the epoxy component. The relative amounts of the epoxy component and monofunctional carboxylic acid may be selected so that the molar amounts of the reactive groups are equal or substantially equal. For example, the ratio of epoxide groups to acid groups may be from 0.5: 1 to 1 :0.5, from 0.75:1 to 1 :0.75, from 0.8: 1 to 1 :0.8, from 0.9: 1 to 1 0.9, or about 1 :1. In some embodiments, the epoxide compound is a diepoxide that incudes two epoxide groups in every molecule. In such embodiments, the molar ratio of the epoxide compound to monofunctional carboxylic acid may be about 1 :2, or from 0.5:2 to 1.5:2, from 0.75:2 to 1.25:2, from 0.8:2 to 1.2:2, from 0.9:2 to 1.1:2.

[0050] The reaction product of the epoxy component and the mono-functional carboxylic acid may be present in the intumescent coating composition at a concentration that results in the desired coating performance.

[0051] The epoxy component and the mono-functional carboxylic acid may be present in the intumescent coating composition at a concentration that results in the reaction product having a concentration of 2 wt-% or higher, 5 wt-% or higher, 10 wt-% or higher, 15 wt-% or higher, 20 wt-% or higher, 25 wt-% or higher, or 30 wt-% or higher. The epoxy component and the monofunctional carboxylic acid may be present in the intumescent coating composition at a concentration that results in the reaction product having a concentration of 60 wt-% or lower, 50 wt-% or lower, 40 wt-% or lower, 35 wt-% or lower, 30 wt-% or lower, 25 wt-% or lower, or 20 wt-% or lower. The reaction product may be present in the intumescent coating composition at a concentration of 2 wt-% to 60 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 12 wt-% to 50 wt- %, 15 wt-% to 50 wt-%, 20 wt-% to 50 wt-%, 25 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 12 wt- % to 40 wt-%, 15 wt-% to 40 wt-%, 20 wt-% to 40 wt-%, 10 wt-% to 35 wt-%, 12 wt-% to 35 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 35 wt-%. The concentration of the reaction product may be given as the concentration in the first part which includes the resin system.

[0052] The resin system includes a monomer mixture. The monomer mixture may act as a reactive solvent. The reactive solvent dissolves at least some of the other components of the resin system, such as the epoxy component and the mono-functional carboxylic acid. The monomer mixture may include one or more polymerizable monomers. Examples of suitable monomers in the monomer mixture include ethylenically unsaturated monomers. The ethylenically unsaturated monomers may include acrylic acid, methacrylic acid, and reaction products (e.g., esters) thereof. Examples of suitable (meth)acrylic ester monomers include methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, and combinations thereof.

[0053] The monomers may be selected from suitable monomers that, when mixed together, the monomer mixture is liquid at room temperature. The monomer mixture may include an ethylenically unsaturated component that is polymerizable by a peroxide.

[0054] The monomer mixture may make up 20 wt-% or more, 30 wt-% or more, 40 wt-% or more, or 50 wt-% or more of the resin system. The monomer mixture may make up 90 wt-% or less, 80 wt-% or less, 70 wt-% or less, or 60 wt-% or less of the resin system. The monomer mixture may make up from 20 wt-% to 90 wt-%, from 30 wt-% to 90 wt-%, or from 40 wt-% to 80 wt-% of the resin system.

[0055] The intumescent coating composition may be free or substantially free of other solvents, other than the monomer mixture. The intumescent coating composition may be free or substantially free of non-polymerizable solvents.

[0056] The monomer mixture may be mixed with an initiator, such as a peroxide, to initiate polymerization. Because the peroxide will typically induce polymerization as soon as it is mixed into the monomer mixture, it may be provided as a separate part of the intumescent coating composition. That is, the intumescent coating composition may be provided as a two-part composition, where a first part includes the monomer mixture (e.g., as part of the resin system) and a second part includes the peroxide. The first part may also include the epoxy component and mono-functional carboxylic acid, or a reaction product of the epoxy component and the mono-functional carboxylic acid. The first part may also include the intumescent component(s), and any optional additional polymer components and additives. The first part may also include an accelerator. To use a two-part composition, the first and second parts may be mixed immediately prior to application, or mixed at the spray gun of a plural spray unit. In some embodiments, the intumescent coating composition may be provided as a three-part composition. In a three-part composition, the first part and second part are similar in that they include the epoxy component and mono-functional carboxylic acid or a reaction product of the epoxy component and the mono-functional carboxylic acid; the intumescent component(s), and any optional additional polymer components and additives. The first part also includes an accelerator, while the second part does not. The third part includes the peroxide. To use a three-part composition, the second and third parts may be mixed prior to application, and this mixture and the first part are mixed at the spray gun of a plural spray unit, or immediately before.

[0057] Suitable peroxides include any compound having a structure containing a structure R-O-O-R (e.g., metal peroxide), organic peroxide compounds with the linkage C-Q-Q-C or C-O-O-H (e.g., dicumyl peroxide, hydrogen peroxide), and combinations of two or more thereof. The initiator may be included at a concentration of 0.05 wt-% or higher, 0.1 wt-% or higher, 0.5 wt-% or higher, 1 wt-% or higher, 2 wt-% or higher, 3 wt-% or higher, 4 wt-% or higher, 5 wt-% or higher, 6 wt-% or higher, or 7 wt-% or higher of the intumescent coating composition (by weight of the total intumescent coating composition, including both parts). The initiator may be included at a concentration of 8 wt-% or lower, 7 wt-% or lower, 6 wt-% or lower, 5 wt-% or lower, 4 wt-% or lower, 3 wt-% or lower, 2 wt-% or lower, 1 wt-% or lower, 0.5 wt-% or lower, or 0.1 wt-% or lower of the intumescent coating composition. The initiator may be included at a concentration of 0.05 wt-% to 8 wt-%, 0.1 wt-% to 7 wt-%, 0.5 wt-% to 6.5 wt-%, or 1 wt-% to 6 wt-% of the intumescent coating composition.

[0058] The polymerization reaction may be accelerated by using an accelerator. The accelerator may be an amine accelerator. Suitable amine accelerators include para-toluidine ethoxylate N,N- dimethylaniline, N,N-dialkyl-p-toluidine compounds (e.g., N,N-dimethyl-p-toluidine, N,N-bis- (2-hydroxypropyl)-p-toluidine, N,N-methyl-n-hydroxyethyl-p-toluidine), and combinations of two or more thereof. The amine accelerator may be included at a concentration of 0 wt-% or higher, 1 wt-% or higher, 2 wt-% or higher, 3 wt-% or higher, 4 wt-% or higher, 5 wt-% or higher, 6 wt-% or higher, 7 wt-% or higher, 8 wt-% or higher, or 9 wt-% or higher based on the amount of peroxide. The amine accelerators may be included at a concentration of 10 wt-% or lower, 9 wt-% or lower, 8 wt-% or lower, 7 wt-% or lower, 6 wt-% or lower, 5 wt-% or lower, 4 wt-% or lower, 3 wt-% or lower, 2 wt-% or lower, or 1 wt-% or lower based on the amount of peroxide. The amine accelerators may be included at a concentration of 0 wt-% to 10 wt-%, 1 wt-% to 9 wt-%, 2 wt-% to 8 wt-%, 3 wt-% to 7 wt-%, or 4 wt-% to 6 wt-% based on the amount of peroxide.

[0059] The resin system may further include a polymer. The polymer may include at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin. The polymer may be or include a (meth)acrylate copolymer. The polymer may be a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2- hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobomyl methacrylate, isobomyl acrylate, benzyl methacrylate, and 2-octyl acrylate. The polymer may include a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters. The polymer may be or include a solid thermoplastic resin.

[0060] The concentration of the polymer may be given as the concentration in the first part which includes the resin system. The polymer may constitute up to 50 wt-%, up to 40 wt-%, up to 30 wt-%, up to 20 wt-%, or up to 10 wt-% of the resin system. The polymer may constitute 10 wt-% or more, 20 wt-% or more, 30 wt-% or more, 40 wt-% or more of the resin system. The polymer may constitute 10 wt-% to 50 wt-%, 15 wt-% to 45 wt-%, 20 wt-% to 40 wt-%, or 25 wt-% to 35 wt-% of the resin system.

[0061] The intumescent coating composition may further include an epoxide-ring-opening catalyst. Any suitable catalyst may be used. Examples of suitable catalysts include tertiary amines, such as pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributyl amine, N-ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, and the like; quaternary ammonium salts, quaternary phosphonium salts; dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethyl phosphonium bromide; imidazole and its derivatives such as 1 -methyl imidazole, 1,2-dimethyl imidazole, 2-methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3-disubstituted imidazolium salts, and the like; N-heterocyclic carbenes or latent N-heterocyclic carbenes, such as 1,3-disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, and the like; Lewis acids such as halides of Al, B, Be, Ti, Zr, Zn, Sn, Fe (III), and the like, and metal alkoxides, metal chelates, and metal oxides, such as zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine; chromium-based (e.g., Cr(III) based or Cr(VI) based) catalysts, such as those available under the tradename HYCAT™ (Dimension Technology Chemical Systems, Inc. in El Dorado Hills, CA); and combinations of two or more thereof. In some embodiments, the catalyst is or includes a chromium-based (e.g., Cr(III) based or Cr(VI) based) catalyst, such as HYCAT™ OA. In some embodiments, it may be desirable to use a catalyst that is free of transition metals. In some embodiments, the catalyst is or includes an imidazole derivative, such as 1,2-dimethyl imidazole.

[0062] The catalyst may be included at any suitable and effective amount. The amount of catalyst may be varied based on the catalyst selected. For example, the catalyst may be included in the intumescent coating composition at a concentration of 1 wt-% or higher, 2 wt-% or higher, 3 wt-% or higher, or 4 wt-% or higher of the epoxy-acid system. The catalyst may be included in the intumescent coating composition at a concentration of 5 wt-% or lower, 4 wt-% or lower, 3 wt-% or lower, or 2 wt-% or lower of the epoxy-acid system. The catalyst may be included in the intumescent coating composition at a concentration of 1 wt-% to 5 wt-%, 1.5 wt-% to 4.5 wt-%, 2 wt-% to 4 wt-%, or 2.5 wt-% to 3.5 wt-% of the epoxy-acid system.

[0063] The intumescent coating composition may also contain various optional additives, such as rheology additives, fdlers, foam stabilizers, pigments, flame spread control agents, and the like.

[0064] Examples of suitable rheology additives that may be used include modified derivatives of castor oil, clays, and solutions of modified urea, and combinations of two or more thereof.

[0065] The fillers may be reinforcing fillers and other suitable fillers. Examples of suitable fillers that may be used include glass fibers, ceramic fibers, graphite fibers, glass flakes, mica, wollastonite, metal oxides, clay, talc, silica, diatomaceous earth, and the like, and combinations thereof. Fillers may be preset at a total concentration of up to 50 wt-% of the intumescent coating composition.

METHODS OF MAKING

[0066] A method of making the intumescent coating composition includes mixing the epoxy component and the mono-functional carboxylic acid to form a reaction product through a ring opening reaction of the epoxy component, and preparing the coating composition by mixing an intumescent component with the reaction product and the monomer mixture.

[0067] The intumescent coating composition may be made by one of two primary methods: (1) preparing the monomer mixture and mixing and dissolving the epoxy component and the monofunctional carboxylic acid in the monomer mixture, where the epoxy component and the mono- functional carboxylic acid react within the monomer mixture; or (2) causing the epoxy component and the mono-functional carboxylic acid to react outside of the monomer mixture, melting the reaction product and mixing the melted reaction product into the monomer mixture. In method (1), the monomer mixture may be heated to a temperature of about 80 °C to 92 °C. In method (2), the reaction product may be heated to a temperature that melts the resins, for example about 150 °C to 160 °C. The molten reaction product may be gradually metered into the monomer mixture to control the temperature increase of the monomers. The reaction between the epoxy component and the mono-functional carboxylic acid may be effected by the addition of an epoxide-ring-opening catalyst, discussed above. Additional ingredients, including the intumescent component and any optional additional polymers and additives, may be added to the composition before or after adding the reaction product.

METHODS OF USING

[0068] Prior to application, the intumescent coating composition may be mixed with an initiator and an accelerator to produce an activated coating composition. The initiator may be a peroxide. Suitable peroxides and concentrations are discussed above. The accelerator may be an amine accelerator. Suitable amine accelerators and concentrations are discussed above.

[0069] The intumescent coating composition may be provided as a two-part composition. The two parts may be mixed together prior to (e.g., immediately prior to) application. The intumescent coating composition may be applied using a spray applicator that mixes the two parts together immediately prior to spraying the composition onto a substrate.

[0070] The intumescent coating composition may be applied to any surface or substrate to be protected against fire. Examples of substrates that the intumescent coating composition may be applied to include metals and metal alloys, e.g., steel, iron, aluminum, and the like; wood, plastic, ceramic, and concrete. In particular, the intumescent coating may be useful for protecting steel structures. The intumescent coating composition may be applied by any suitable method, such as spraying, brushing, or rolling. In many architectural applications, the intumescent coating composition is applied by spraying. The intumescent coating composition may be mixed prior to application or during application. The intumescent coating composition may be applied using a single spray applicator or a dual spray applicator. In some embodiments, the intumescent coating composition is mixed prior to application and is applied by spraying using a single spray applicator.

[0071] The intumescent coating composition may be applied in a thickness that provides full coverage of the substrate being coated. For example, the intumescent coating composition may be applied at a thickness of at least 400 pm (micrometer), at least 500 pm, at least 700 pm, at least 900 pm, at least 1000 pm, at least 1200 pm, at least 1400 pm, at least 1700 pm, or at least 1900 pm. The intumescent coating composition may be applied at a thickness of up to 2000 pm, up to 1800 pm, up to 1500 pm, up to 1300 pm, up to 1100 pm, up to 900 pm, up to 700 pm, up to 600 pm, or up to 500 pm. The intumescent coating composition may be applied at a thickness of 400 pm to 2000 pm, 500 pm to 1800 pm, 600 pm to 1700 pm, 700 pm to 1600 pm, 800 pm to 1500 pm, 900 pm to 14000 pm, 1000 pm to 13000 pm, orl lOO pm to 12000 pm.

[0072] The intumescent coating composition may be relatively quick drying. That is, after application, the intumescent coating composition may form a solid within 60 minutes or less at a temperature of 25 °C or less, at a temperature of 20 °C or less, at a temperature of 15 °C or less, or at a temperature of 7 °C to 13 °C. Only a small amount, if any, of volatiles are lost from the intumescent coating composition upon curing. For example, less than 10 wt-%, less than 8 wt-%, less than 5 wt-%, or less than 2 wt-% of volatile components by weight of the intumescent coating composition are lost during curing. Due to the low loss of volatiles, the finished intumescent coating has a thickness that is substantially similar to the applied coating composition thickness discussed above. For example, the finished intumescent coating thickness may be 90 % or greater, 95 % or greater, or 98 % or greater of the applied coating composition thickness.

[0073] The intumescent coating composition is curable by free radical polymerization. The reaction product of the epoxide component and the mono-functional carboxylic acid migrates to the surface of the coating, creating a passivating layer, below which the monomers (and any other polymerizable components that may be present) react via free-radical polymerization. The passivating layer allows the free-radical polymerization to progress without oxygen inhibition.

[0074] The intumescent coating composition may form a thin, hard coating. The hardness of the coating may be evaluated by measuring its Shore hardness, e.g., by using ASTM 2240 method. Shore harness indicates the force needed to indent the tested material and may be used to evaluate the hardness of materials such as plastics, rubbers, and elastomers. Shore harness values range from 0 to 100. The cured intumescent coating may have a Shore D hardness of 40 or greater, 45 or greater, or 50 or greater, measured 24 hours after application. The cured intumescent coating may have a Shore D hardness of 90 or lower, 80 or lower, or 70 or lower, measured 24 hours after application. The cured intumescent coating may have a Shore D hardness of 40 to 90 or 45 to 70, measured 24 hours after application.

EMBODIMENTS

[0075] The following is a list of exemplary embodiments according to the present disclosure.

[0076] Embodiment 1 is an intumescent coating composition comprising a resin system comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component, wherein the composition is curable by free radical polymerization.

[0077] Embodiment 2 is the intumescent coating composition of embodiment 1, wherein the epoxy component and the mono-functional carboxylic acid are dissolvable in the monomer mixture.

[0078] Embodiment 3 is the intumescent coating composition of any one of embodiments 1 or 2, wherein the reaction product is dissolved in the monomer mixture.

[0079] Embodiment 4 is the intumescent coating composition of any one of embodiments 1 to 3, wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

[0080] Embodiment 5 is the intumescent coating composition of any one of embodiments 1 to 4, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C, optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher, 25 °C or higher, or 30 °C or higher.

[0081] Embodiment 6 is the intumescent coating composition of any one of embodiments 1 to 5, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000, from 800 to 4600, from 1000 to 4000, from 1500 to 3000, or from 1800 to 2500.

[0082] Embodiment 7 is the intumescent coating composition of any one of embodiments 1 to 6, wherein the mono-functional carboxylic acid comprises butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)3COOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)6COOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)SCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)ioCOOH), tridecanoic acid (CH3(CH2)nCOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)i5COOH), octadecanoic (stearic) acid (CH3(CH2)i6COOH), octadecadienoic (linoleic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)i?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH2)i4COOH).

[0083] Embodiment 8 is the intumescent coating composition of any one of embodiments 1 to 7, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1 ,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof. [0084] Embodiment 9 is the intumescent coating composition of any one of embodiments 1 to 8, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0085] Embodiment 10 is the intumescent coating composition of any one of embodiments 1 to

9, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

[0086] Embodiment 11 is the intumescent coating composition of any one of embodiments 1 to

10, further comprising an epoxide-ring-opening catalyst.

[0087] Embodiment 12 is the intumescent coating composition of claim 11, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N- ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenyl ethyl phosphonium bromide, 1 -methyl imidazole, 1,2-dimethyl imidazole, 2- methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3 -di substituted imidazolium salt, 1,3- disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3- disubstituted imidazolium acetate, halide of Al, B, Be, Ti, Zr, Zn, Sn, or Fe (III), zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine, a chromium- based catalyst, or a combination of two or more thereof.

[0088] Embodiment 13 is the intumescent coating composition of claim 11 or 12, wherein the catalyst comprises 1,2-dimethyl imidazole.

[0089] Embodiment 14 is the intumescent coating composition of any one of embodiments 1 to 13, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof. [0090] Embodiment 15 is the intumescent coating composition of any one of embodiments 1 to

14, wherein the intumescent coating composition is a two-part composition, wherein a first part comprises the reaction product, the monomer mixture, and the intumescent component, and wherein a second part comprises a peroxide initiator.

[0091] Embodiment 16 is the intumescent coating composition of any one of embodiments 1 to

15, wherein the second part further comprises an amine accelerator.

[0092] Embodiment 17 is the intumescent coating composition of any one of embodiments 1 to

16, wherein the resin system further comprises a polymer.

[0093] Embodiment 18 is the intumescent coating composition of embodiment 17, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0094] Embodiment 19 is the intumescent coating composition of embodiment 17 or 18, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

[0095] Embodiment 20 is the intumescent coating composition of any one of embodiments 17 to

19, wherein the polymer comprises a solid thermoplastic resin.

[0096] Embodiment 21 is the intumescent coating composition of any one of embodiments 17 to

20, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

[0097] Embodiment 22 is the intumescent coating composition of any one of embodiments 17 to

21, wherein the composition is free of solvents other than the monomer mixture.

[0098] Embodiment 23 is the intumescent coating composition of any one of embodiments 1 to

22, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight. [0099] Embodiment 24 is the intumescent coating composition of any one of embodiments 1 to

23, wherein the reaction product constitutes from 2 % to 60 % of the intumescent coating composition by weight.

[0100] Embodiment 25 is the intumescent coating composition of any one of embodiments 1 to

24, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

[0101] Embodiment 26 is a method of making an intumescent coating composition, the method comprising: mixing an epoxy component and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons to form a reaction product through a ring opening reaction of the epoxy component; and preparing the coating composition by mixing an intumescent component with the reaction product and a monomer mixture comprising at least one ethylenically unsaturated monomer. [0102] Embodiment 27 is the method of embodiment 26, wherein the epoxy component and the mono-functional carboxylic acid are mixed with and dissolved in the monomer mixture prior to forming the reaction product.

[0103] Embodiment 28 is the method of any one of embodiments 26 to 27, wherein the reaction product is formed prior to mixing the reaction product with the monomer mixture.

[0104] Embodiment 29 is the method of any one of embodiments 26 to 28, wherein the monofunctional carboxylic acid comprises butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)3COOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)eCOOH), nonanoic (pelargoic) acid (CH (CH2)?COOH), decanoic (capric) acid (CH (CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)IOCOOH), tridecanoic acid (CH3(CH2)IICOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ieCOOH), octadecadienoic (linoleic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH₂)14COOH).

[0105] Embodiment 30 is the method of any one of embodiments 26 to 29, comprising mixing an epoxide-ring-opening catalyst with the epoxy component and the mono-functional carboxylic acid.

[0106] Embodiment 31 is the method of embodiment 30, wherein the catalyst comprises 1,2- dimethyl imidazole.

[0107] Embodiment 32 is the method of any one of embodiments 26 to 31, wherein the epoxy component comprises wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

[0108] Embodiment 33 is the intumescent coating composition of any one of embodiments 26 to

32, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C, optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher, 25 °C or higher, or 30 °C or higher.

[0109] Embodiment 34 is the intumescent coating composition of any one of embodiments 26 to

33, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000, from 800 to 4600, from 1000 to 4000, from 1500 to 3000, or from 1800 to 2500.

[0110] Embodiment 35 is the intumescent coating composition of any one of embodiments 26 to

34, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0111] Embodiment 36 is the intumescent coating composition of any one of embodiments 26 to

35, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0112] Embodiment 37 is the intumescent coating composition of any one of embodiments 26 to

36, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0113] Embodiment 38 is the intumescent coating composition of any one of embodiments 26 to

37, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

[0114] Embodiment 39 is the method of any one of embodiments 26 to 38, further comprising mixing the intumescent component with a polymer.

[0115] Embodiment 40 is the method of embodiment 39, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0116] Embodiment 41 is the method of embodiment 39 or 40, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n- butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2- hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobomyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

[0117] Embodiment 42 is the method of any one of embodiments 39 to 41, wherein the polymer comprises a solid thermoplastic resin.

[0118] Embodiment 43 is the method of any one of embodiments 39 to 42, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

[0119] Embodiment 44 is the method of any one of embodiments 26 to 43, wherein the composition is free of solvents other than the monomer mixture.

[0120] Embodiment 45 is the method of any one of embodiments 26 to 44, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

[0121] Embodiment 46 is the method of any one of embodiments 26 to 45, wherein the reaction product constitutes from 2 wt-% to 60 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 12 wt-% to 50 wt-%, 15 wt-% to 50 wt-%, 20 wt-% to 50 wt-%, 25 wt-% to 50 wt-%, 10 wt-% to 40 wt- %, 12 wt-% to 40 wt-%, 15 wt-% to 40 wt-%, 20 wt-% to 40 wt-%, 10 wt-% to 35 wt-%, 12 wt- % to 35 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 35 wt-% of the intumescent coating composition by weight.

[0122] Embodiment 47 is the method of any one of embodiments 26 to 46, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

[0123] Embodiment 48 is the method of any one of embodiments 26 to 47, further comprising mixing the composition with a peroxide initiator.

[0124] Embodiment 49 is the method of any one of embodiments 26 to 48, further comprising mixing the composition with an amine accelerator.

[0125] Embodiment 50 is the method of any one of embodiments 26 to 49, wherein the composition is curable by free radical polymerization. [0126] Embodiment 51 is a method of coating a substrate with an intumescent coating, the method comprising: mixing a liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition, the liquid intumescent coating composition comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component; applying the activated coating composition onto the substrate; and allowing the activated coating composition to cure under ambient conditions into a solid state to form the intumescent coating.

[0127] Embodiment 52 is the method of embodiment 51, wherein the liquid intumescent coating composition cures via free radical polymerization.

[0128] Embodiment 53 is the method of embodiment 51 or 52, wherein the epoxy component and the mono-functional carboxylic acid are dissolved in the monomer mixture.

[0129] Embodiment 54 is the method of any one of embodiments 51 to 53, wherein the reaction product is dissolved in the monomer mixture.

[0130] Embodiment 55 is the method of any one of embodiments 51 to 54, wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

[0131] Embodiment 56 is the intumescent coating composition of any one of embodiments 51 to

55, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C, optionally wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher, 25 °C or higher, or 30 °C or higher.

[0132] Embodiment 57 is the intumescent coating composition of any one of embodiments 51 to

56, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000, from 800 to 4600, from 1000 to 4000, from 1500 to 3000, or from 1800 to 2500.

[0133] Embodiment 58 is the intumescent coating composition of any one of embodiments 51 to

57, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0134] Embodiment 59 is the intumescent coating composition of any one of embodiments 51 to

58, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0135] Embodiment 60 is the intumescent coating composition of any one of embodiments 51 to

59, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof. [0136] Embodiment 61 is the intumescent coating composition of any one of embodiments 51 to 60, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

[0137] Embodiment 62 is the method of any one of embodiments 51 to 61, wherein the liquid intumescent coating composition further comprises a polymer.

[0138] Embodiment 63 is the method of embodiment 62, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0139] Embodiment 64 is the method of embodiment 62 or 63, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n- butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2- hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobomyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

[0140] Embodiment 65 is the method of any one of embodiments 62 to 64, wherein the polymer comprises a solid thermoplastic resin.

[0141] Embodiment 66 is the method of any one of embodiments 62 to 65, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

[0142] Embodiment 67 is the method of any one of embodiments 51 to 66, wherein the initiator comprises an organic peroxide, optionally wherein the organic peroxide comprises a diacyl peroxide, a ketone peroxide, a peroxyester, a dialkyl peroxide, a hydroperoxide, a peroxyketal, or a combination of two or more thereof.

[0143] Embodiment 68 is the method of any one of embodiments 51 to 67, wherein the composition is free of solvents other than the monomer mixture.

[0144] Embodiment 69 is the method of any one of embodiments 51 to 68, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight. [0145] Embodiment 70 is the method of any one of embodiments 51 to 69, wherein the reaction product constitutes from 2 wt-% to 60 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 12 wt-% to 50 wt-%, 15 wt-% to 50 wt-%, 20 wt-% to 50 wt-%, 25 wt-% to 50 wt-%, 10 wt-% to 40 wt- %, 12 wt-% to 40 wt-%, 15 wt-% to 40 wt-%, 20 wt-% to 40 wt-%, 10 wt-% to 35 wt-%, 12 wt- % to 35 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 35 wt-% of the intumescent coating composition by weight.

[0146] Embodiment 71 is the method of any one of embodiments 51 to 70, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

[0147] Embodiment 72 is the method of any one of embodiments 51 to 71, wherein the activated coating composition is cured in 60 minutes or less at a temperature of 25 °C or less, optionally at a temperature of 20 °C or less, optionally at a temperature of 15 °C or less, optionally at a temperature of 7 °C to 13 °C.

[0148] Embodiment 73 is the method of any one of embodiments 51 to 72, wherein less than 5 % by weight of volatile components is lost by evaporation during the curing.

[0149] Embodiment 74 is the method of any one of embodiments 51 to 73, wherein the intumescent coating has a Shore D hardness of 45 to 90 or 45 to 70, measured 24 hours after application.

[0150] Embodiment 75 is the method of any one of embodiments 51 to 74, wherein the monofunctional carboxylic acid comprises butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)3COOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)eCOOH), nonanoic (pelargoic) acid (CH (CH2)?COOH), decanoic (capric) acid (CH (CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)IOCOOH), tridecanoic acid (CEh(CH2)iiCOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ieCOOH), octadecadienoic (linoleic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH₂)14COOH).

[0151] Embodiment 76 is a kit for applying an intumescent coating to a substrate, the kit comprising: a first part comprising a resin system comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component; and a second part comprising a peroxide initiator and an amine accelerator.

[0152] Embodiment 77 is the kit of embodiment 76, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C.

[0153] Embodiment 78 is the kit of embodiment 76 or 77, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000, from 800 to 4600, from 1000 to 4000, from 1500 to 3000, or from 1800 to 2500.

[0154] Embodiment 79 is the kit of any one of embodiments 76 to 78, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher, 25 °C or higher, or 30 °C or higher.

[0155] Embodiment 80 is the kit of any one of embodiments 76 to 79, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3 -propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0156] Embodiment 81 is the kit of any one of embodiments 76 to 80, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

[0157] Embodiment 82 is the kit of any one of embodiments 76 to 81, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

[0158] Embodiment 83 is the kit of any one of embodiments 76 to 82, wherein the monofunctional carboxylic acid comprises butanoic (butyric) acid (CHB(CH2)2COOH), pentanoic (valeric) acid (CHa(CH2)3COOH), hexanoic (caproic) acid (CHB(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)eCOOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)ioCOOH), tridecanoic acid (CH3(CH2)HCOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ieCOOH), octadecadienoic (linoleic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH₂)i4COOH).

[0159] Embodiment 84 is the kit of any one of embodiments 76 to 83, further comprising an epoxide-ring-opening catalyst. [0160] Embodiment 85 is the kit of embodiment 84, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethyl phosphonium bromide, 1 -methyl imidazole, 1,2-dimethyl imidazole, 2-methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3-disubstituted imidazolium salt, 1,3 -di substituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halide of Al, B, Be, Ti, Zr, Zn, Sn, or Fe (III), zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine, a chromium-based catalyst, or a combination of two or more thereof.

[0161] Embodiment 86 is the kit of embodiment 85, wherein the catalyst comprises 1,2-dimethyl imidazole.

[0162] Embodiment 87 is the kit of any one of embodiments 76 to 86, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

[0163] Embodiment 88 is the kit of any one of embodiments 76 to 87, wherein the resin system further comprises a polymer.

[0164] Embodiment 89 is the kit of embodiment 88, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

[0165] Embodiment 90 is the kit of embodiment 88 or 89, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n- butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2- hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobomyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

[0166] Embodiment 91 is the kit of any one of embodiments 88 to 90, wherein the polymer comprises a solid thermoplastic resin.

[0167] Embodiment 92 is the kit of any one of embodiments 88 to 91, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

[0168] Embodiment 93 is the kit of any one of embodiments 76 to 92, wherein the composition is free of solvents other than the monomer mixture.

[0169] Embodiment 94 is the kit of any one of embodiments 76 to 93, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

[0170] Embodiment 95 is the kit of any one of embodiments 76 to 94, wherein the reaction product constitutes from 2 wt-% to 60 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 12 wt-% to 50 wt-%, 15 wt-% to 50 wt-%, 20 wt-% to 50 wt-%, 25 wt-% to 50 wt-%, 10 wt-% to 40 wt- %, 12 wt-% to 40 wt-%, 15 wt-% to 40 wt-%, 20 wt-% to 40 wt-%, 10 wt-% to 35 wt-%, 12 wt- % to 35 wt-%, 15 wt-% to 35 wt-%, or 20 wt-% to 35 wt-% of the intumescent coating composition by weight.

[0171] Embodiment 96 is the kit of any one of embodiments 76 to 95, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

EXAMPLES

[0172] Various compositions were prepared with and without a reaction product of an epoxy component and a carboxylic acid.

MATERIALS

METHODS

[0173] Preparation of Reaction Product (Adduct) of Epoxide Component and Carboxylic Acid

[0174] To a 1000 ml round-bottom reaction flask was added epoxy resin, long chain carboxylic acid, butylated hydroxytoluene (BHT) as a free-radical inhibitor, and monomers. The mixture was heated with stirring (agitation) until it formed a clear solution. To the solution were added 1,2-dimethyl imidazole (heterocyclics), carbene, or a chromium (VI) catalysts and the reaction was allowed to proceed. Unless otherwise stated, the reaction was performed at 87 °C (86 °C for the chromium (VI) catalyst).

Preparation of Coating

[0175] The following amounts were used unless otherwise stated. To a 20-gram sample of the adduct and monomer(s), 1 wt-% of an amine accelerator para-toluidine ethoxylate (BISOMER® PTE; N,N-bis-(2-hydroxyethyl)-para-toluidine, which is an aromatic tertiary amine used as an amine activator for organic peroxide), and 0.4 wt-% benzoyl peroxide (LUPEROX® AFR40: 40% benzoyl peroxide in dibutyl phthalate) (1 wt-% for compositions including chromium (VI) catalyst) were added. The mixture was mixed until it has a uniform appearance and poured into a metal pan and allowed to harden.

Hardness Test

[0176] The relative hardness of the coating is measured through the ability of a circular or rounded piece of wood to indent into the polymer. The relative hardness test is configured to give a relative measurement based on the indent of a test object. During the relative hardness test, the circular piece of wood is manually pressed against and indented on the surface of the test object. The indentation of the test object indicates the relative hardness by visual estimation. The relative indentation is rated from 1 (still liquid) to 10 (very hard solid).

Tackiness Test

[0177] Tackiness of a coating can be measured by measuring the amount of sand that can adhere to the surface of the coating.

[0178] A coating is applied onto a metal pan, and allowed to cure for 24 hours. After hardening/curing, the pan with the coating is weighed. An amount of sand that fully covers the surface of the coating is added onto the coating, and a weight of 100 grams is placed on the sand for one minute at room temperature (about 20 °C). The weight is removed, loose sand is poured off by turning the pan upside down and lightly tapping. The pan and the contents (including the coating) are weighed again. The change in weigh is the amount of sand that adhered to the coating and is a measure of the tackiness of the cured coating.

Example 1, Comparative Coating

[0179] A comparative coating sample without the adduct was prepared. A resin mixture was prepared by mixing 10 grams of DEGALAN® 1720 and 10 grams of DEGALAN® 1710 together and mixed with 1.6 grams of LUPEROX® AFR40 (40 % benzoyl peroxide in dibutyl phthalate). DEGALAN 1710 and 1720 are acrylic monomer mixtures that contain methyl methacrylate (“MMA”) and 2-ethylhexyl acrylate (“2EHA”). The mixture was poured into an aluminum pan to allow to cure for 24 hours in air and under room temperature. Samples contained 75:25 wt % MMA:2EHA.

Example 2

[0180] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared.

[0181] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using 1,2-dimethyl imidazole. EPON 1004F is a diepoxide having a molecular weight of about 1750. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 1 below. The coating composition was prepared as explained above, adding to the mixture 0.22 g of an amine accelerator and 1 .61 g of benzoyl peroxide. The coating composition was applied to a surface and cured in air at room temperature.

TABLE 1.

[0182] The properties of the coating composition of Example 2 were evaluated and compared to the comparative sample of Example 1. The results are shown in TABLE 2.

TABLE 2.

[0183] It was observed that a hard, essentially tack free coating could be produced from the composition.

Example 3

[0184] A coating composition including a mixture of MMA, 2-octyl acrylate, and an adduct was prepared.

[0185] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCAT OA. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 3 below. The coating composition was prepared as explained above. The amine accelerator was added to the MMA/EHA adduct and then 2.3 g of benzoyl peroxide was added to the mixture. The coating composition was applied to a surface and cured in air at room temperature. TABLE 3.

[0186] The final solids content of the coating composition was 30 wt-%. The acid number of the coating composition was 37.5, and total conversion was 97.6 % (comparison between measured solids and calculated solids).

Example 4

[0187] A coating composition similar to Example 3, using a different amount of catalyst, was prepared.

[0188] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCAT OA. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 4 below. The coating composition was prepared as explained above. The amine accelerator was added to the MMA/EHA adduct and then 2.3 g of benzoyl peroxide was added to the mixture. The coating composition was applied to a surface and cured in air at room temperature.

TABLE 4. [0189] The final solids content of the coating composition was 27 wt-%. The acid number of the coating composition was 41.3, and total conversion was 88.3 % (comparison between measured solids and calculated solids).

[0190] The properties of the coating compositions of Examples 3 and 4 were evaluated and compared to each other and the comparative sample of Example 1. The results are shown in TABLE 5.

TABLE 5.

[0191] It was observed that the coating could be prepared by using 2-octyl acrylate.

Example 5

[0192] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared.

[0193] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using l,3-dimethyl-lH-imidazol-3-ium-2-carboxylate as a catalyst. The catalyst had a molecular weight of 140.14. The reaction was run at 80 °C for 5 hours. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 6 below. The coating composition was prepared as explained above, adding to the mixture 0.22 g of an amine accelerator and 1.61 g of benzoyl peroxide. The coating composition was applied to a surface and cured in air at room temperature. Lithium chloride in TABLE 6 used as an accelerator for the catalyst.

TABLE 6.

[0194] The final solids content of the coating composition was 52.25 wt-%. The acid number of the coating composition was 49.4, and total conversion was 106.79 % (comparison between measured solids and calculated solids).

[0195] The properties of the coating composition were evaluated. The results are shown in TABLE 7.

TABLE 7.

Example 6

[0196] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared.

[0197] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using a l,3-dimethyl-lH-imidazol-3-ium-2-carboxylate as catalyst. The reaction was run at 80 °C for 5 hours. The catalyst had a molecular weight of 140.14 g/mol. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 8 below. The coating composition was prepared as explained above, adding to the mixture 0.22 g of an amine accelerator and 1.61 g of benzoyl peroxide. The coating composition was applied to a surface and cured in air at room temperature.

TABLE 8.

[0198] The final solids content of the coating composition was 52.43 wt-%. The acid number of the coating composition was 0.54, and total conversion was 106.51 % (comparison between measured solids and calculated solids).

[0199] The properties of the coating composition were evaluated. The results are shown in TABLE 9.

TABLE 9.

Example 7

[0200] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared.

[0201] The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using a 3-benzyl-l,2-dimethyl-lH-imidazol-3-ium chloride as catalyst. The reaction was run at 80 °C for 5 hours. The catalyst had a molecular weight of 222.72 g/mol. The resulting adduct was mixed with an acrylic monomer mixture. The amounts of components are shown in TABLE 10 below. The coating composition was prepared as explained above, adding to the mixture 0.22 g of an amine accelerator and 1.61 g of benzoyl peroxide. The coating composition was applied to a surface and cured in air at room temperature.

TABLE 10. [0202] The final solids content of the coating composition was 54.45 wt-% (shown as Sample A in TABLE 11). The acid number of the coating composition was 1.25, and total conversion was 109.9 % (comparison between measured solids and calculated solids).

[0203] Another coating composition was prepared using the same chemical composition but only half the solids — 27.2 wt-% (shown as Sample B in TABLE 11).

[0204] The properties of the coating compositions at two different solids levels were evaluated. The results are shown in TABLE 11.

TABLE 11.

Example 8

[0205] Various coating compositions were prepared to test different catalysts. The compositions were otherwise similar. The compositions are shown in TABLE 12. The catalysts in samples 1-5 resulted in 100 % ring opening; the catalyst in sample 6 resulted in 99 % ring opening. Degree of ring opening was evaluated using 1H-NMR. The samples were also tested for hardness and tack. The results are shown in TABLE 13.

TABLE 12.

TABLE 13.

Example 9

[0206] Two resin compositions were prepared according to embodiments of the present disclosure. The resin compositions were mixed with intumescent and other components to prepare intumescent coating compositions, which were subjected to fire testing. The samples were compared to a prior art standard coating material (Comparative Sample).

[0207] An adduct was prepared from EPON 1004 (molecular weight 1750 g/mol) as the epoxy component and lauric acid (molecular weight 200.3 g/mol; Sample 12A) or palmitic acid (molecular weight 256.4 g/mol; Sample 12B) as the carboxylic acid. 1,2 dimethyl imidazole (DMI) was used as a catalyst and BHT as the free-radical inhibitor. The adduct was reacted at a temperature of 150 °C. The preparation of the adduct included no solvent. After the adduct was prepared, it was mixed with the monomers. The resin mixture compositions are shown in TABLE 14.

TABLE 14.

[0208] The resin mixtures (the adduct and monomer mixtures from TABLE 14) of Samples 12A and 12B were mixed with the same intumescent and additional components as in the Comparative Sample. The resin used in the Comparative Sample was DEGALAN. Samples 12A and 12B and the Comparative Sample each included about 35 wt-% of resins. The intumescent and additional materials included about 50 wt-% of intumescent components (a mixture of ammonium polyphosphate, melamine, and pentaerythritol); about 15 wt-% of fillers; about 1-2 wt-% of additives, and about 1 wt-% of peroxide.

[0209] Samples 12A and 12B were tested for their hardness and tack. The coatings were applied onto hot-rolled steel panels of 300 mm x 200 mm x 5 mm in size and subjected to a heating curve according to BS EN1363-1 :2020 fire resistance test. The thickness of the coating was measured before and after heating. The results are shown in TABLE 15.

TABLE 15.

Example 10

[0210] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared. The adduct was prepared by reacting EPON 1004F with a long chain carboxylic acid (palmitic acid) via a catalytic reaction using HYCAT OA. The amounts of components are shown in TABLE 16 below.

TABLE 16.

[0211] The coating composition was prepared as explained above, varying the amount of the adduct mixed with the acrylic monomer mixture, and adding an amine accelerator and peroxide, as shown in TABLE 17. The acid number of the coating composition was 3.46. The coating composition was applied to a surface and cured in air at room temperature. The hardness (on a scale of 1-10) of the coatings was evaluated after 30 min, 60 min, and 120 min. The tackiness (amount of adhered sand (g)) was evaluated at 24 hours. The results are shown in TABLE 17.

TABLE 17, (all amounts in wt-%) [0212] It was observed that a hard, essentially tack free coating could be produced from the compositions with about 20 wt-% or more of adduct. The samples hardened faster and produced a harder coating with increasing amounts of adduct.

Example 11

[0213] Coatings with varying amounts of adduct were prepared to test the properties of the coatings. The samples were prepared as in Example 10. The amounts of components are shown in TABLE 18 below. Compared to Example 10, the adduct was prepared with a higher amount of catalyst.

TABLE 18.

[0214] The amount of the adduct mixed with the acrylic monomer mixture (with 1.15 wt% amine and 3.05 wt-% peroxide, by weight of the final mixture) was varied as shown in TABLE 19. The acid number of the coating composition was 1.91. The coating composition was applied to a surface and cured in air at room temperature. The hardness (on a scale of 1-10) of the coatings was evaluated after 30 min, 60 min, and 120 min. The tackiness (amount of adhered sand (g)) was evaluated at 24 hours. The results are shown in TABLE 19.

TABLE 19, (all amounts in wt-%)

[0215] It was observed that an essentially tack free coating could be produced from the compositions at all tested adduct. The samples hardened faster and produced a harder coating with increasing amounts of adduct. Example 12

[0216] Coatings with varying amounts of adduct and EPON 1007F and palmitic acid were prepared to test the properties of the coatings. EPON 1007F is a di epoxide having a molecular weight of about 1700-2300. The samples were prepared as in Example 10. The amounts of components are shown in TABLE 20 below.

TABLE 20.

[0217] The amount of the adduct mixed with the acrylic monomer mixture was varied as shown in TABLE 21. The coating composition was applied to a surface and cured in air at room temperature. The hardness (on a scale of 1-10) of the coatings was evaluated after 30 min, 60 min, 90 min, and 120 min. The results are shown in TABLE 21.

TABLE 21 (all amounts in wt-%)

Example 13

[0218] Example 10 was repeated except using cyclohexyl methacrylate as the monomer. The adduct was prepared as in Example 10, using EPON 1004F, palmitic acid, and HYCAT OA. [0219] The coating composition was prepared as explained above, varying the amount of the adduct mixed with the acrylic monomer mixture, and adding an amine accelerator and peroxide, as shown in TABLE 22. The acid number of the coating composition was 0.72. The coating composition was applied to a surface and cured in air at room temperature for 15 minutes. The hardness (on a scale of 1-10) of the coatings was evaluated after 1 hour. The tackiness (amount of adhered sand (g)) was evaluated at 48 hours. The results are shown in TABLE 22.

TABLE 22, (all amounts in wt-%)

[0220] It was observed that a hard, essentially tack free coating could be produced from the compositions with about 20 wt-% or more of adduct. The samples hardened faster and produced a harder coating with increasing amounts of adduct.

Example 14

[0221] A coating composition including a mixture of MMA, 2EHA, and an adduct was prepared. The adduct was prepared by reacting EPON 1004F, trimethylolpropane triacrylate, and butyl acrylate with a long chain carboxylic acid (stearic acid) via a catalytic reaction using HYCAT OA. The amounts of components are shown in TABLE 23 below.

TABLE 23. [0222] The adduct was mixed with 377.3 g of MMA, 94.3 g of 2EHA, 0.50 wt-% of benzoyl peroxide, and 0.2 wt-% of amine. The acid number of the composition was 0.82; solids were 39.38 %, and conversion rate was 97.60 %. The sample cured in 45 minutes to a solid.

[0223] The sample was analyzed by therm ogravimetric analysis (TGA). The heating was conducted using a heating profile from 25 °C to 850 °C at 20 °C/min, in air flow at about 200 mL/min. The sample was compared to two commercially available products. The TGA graph is shown in FIG. 1. The sample was found to be soft but without any tackiness.

Example 15

Coating compositions with varying adduct compositions were made and analyzed using TGA. The samples were prepared as described in Example 12, using MMA/2EHA as the monomer. The amounts of epoxy, carboxylic acids, HYCAT OA, and BHT in the adduct are shown in TABLE 24 below.

TABLE 24, (all amounts in wt-%, by weight of the adduct)

[0224] The samples were cured in air at room temperature to a soft but tack free product. The samples were analyzed by TGA as described in Example 14, and compared to a commercially available product. The TGA graphs are shown in FIGS. 2A-2D. The resulting products were found to extend the thermal stability beyond the commercially available product.

[0225] All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth here.

Claims

1. An intumescent coating composition comprising a resin system comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component, wherein the composition is curable by free radical polymerization.

2. The intumescent coating composition of claim 1, wherein the epoxy component and the mono-functional carboxylic acid are dissolvable in the monomer mixture.

3. The intumescent coating composition of claim 1 or 2, wherein the reaction product is dissolved in the monomer mixture.

4. The intumescent coating composition of any one of claims 1 to 3, wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

5. The intumescent coating composition of any one of claims 1 to 4, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C.

6. The intumescent coating composition of any one of claims 1 to 5, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000.

7. The intumescent coating composition of any one of claims 1 to 6, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher.

8. The intumescent coating composition of any one of claims 1 to 7, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3 -propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from 1,3 -bi s(aminom ethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

9. The intumescent coating composition of any one of claims 1 to 8, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

10. The intumescent coating composition of any one of claims 1 to 9, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

11. The intumescent coating composition of any one of claims 1 to 10, further comprising an epoxide-ring-opening catalyst.

12. The intumescent coating composition of claim 11, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N- ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethyl phosphonium bromide, 1 -methyl imidazole, 1,2-dimethyl imidazole, 2- methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3 -di substituted imidazolium salt, 1,3- disubstituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3- disubstituted imidazolium acetate, halide of Al, B, Be, Ti, Zr, Zn, Sn, or Fe (III), zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine, a chromium- based catalyst, or a combination of two or more thereof.

13. The intumescent coating composition of claim 12, wherein the catalyst comprises 1,2- dimethyl imidazole.

14. The intumescent coating composition of any one of claims 1 to 13, wherein the monofunctional carboxylic acid comprises butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)BCOOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)5COOH), octanoic (caprylic) acid (CH3(CH2)eCOOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)IOCOOH), tridecanoic acid (CH3(CH2)IICOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH2)i4COOH).

15. The intumescent coating composition of any one of claims 1 to 14, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

16. The intumescent coating composition of any one of claims 1 to 15, wherein the intumescent coating composition is a two-part composition, wherein a first part comprises the reaction product, the monomer mixture, and the intumescent component, and wherein a second part comprises a peroxide initiator.

17. The intumescent coating composition of claim 16, wherein the second part further comprises an amine accelerator.

18. The intumescent coating composition of any one of claims 1 to 17, wherein the resin system further comprises a polymer.

19. The intumescent coating composition of claim 18, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

20. The intumescent coating composition of claim 18 or 19, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n- butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2- hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobornyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

21. The intumescent coating composition of any one of claims 1 to 20, wherein the polymer comprises a solid thermoplastic resin.

22. The intumescent coating composition of any one of claims 1 to 21, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

23. The intumescent coating composition of any one of claims 1 to 22, wherein the composition is free of solvents other than the monomer mixture.

24. The intumescent coating composition of any one of claims 1 to 23, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

25. The intumescent coating composition of any one of claims 1 to 24, wherein the reaction product constitutes from 2 % to 60 % of the intumescent coating composition by weight.

26. The intumescent coating composition of any one of claims 1 to 25, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

27. A method of making an intumescent coating composition, the method comprising: mixing an epoxy component and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons to form a reaction product through a ring opening reaction of the epoxy component; and preparing the coating composition by mixing an intumescent component with the reaction product and a monomer mixture comprising at least one ethylenically unsaturated monomer.

28. The method of claim 27, wherein the epoxy component and the mono-functional carboxylic acid are mixed with and dissolved in the monomer mixture prior to forming the reaction product.

29. The method of claim 27 or 28, wherein the reaction product is formed prior to mixing the reaction product with the monomer mixture.

30. The method of any one of claims 27 to 29, wherein the composition is curable by free radical polymerization.

31. The method of any one of claims 27 to 30, comprising mixing an epoxide-ring-opening catalyst with the epoxy component and the mono-functional carboxylic acid.

32. The method of claim 31, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethyl phosphonium bromide, 1 -methyl imidazole, 1,2-dimethyl imidazole, 2-methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3-disubstituted imidazolium salt, 1,3 -di substituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halide of Al, B, Be, Ti, Zr, Zn, Sn, or Fe (III), zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine, a chromium-based catalyst, or a combination of two or more thereof.

33. The method of claim 31, wherein the catalyst comprises 1,2-dimethyl imidazole.

34. The method of any one of claims 27 to 33, wherein the mono-functional carboxylic acid comprises butanoic (butyric) acid (CHa(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)SCOOH), hexanoic (caproic) acid (CHa(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)SCOOH), octanoic (caprylic) acid (CH (CH2)fiCOOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)ioCOOH), tridecanoic acid (CH3(CH2)IICOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH (CH2)ISCOOH), octadecanoic (stearic) acid (CH (CH2)i6COOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH2)i4COOH).

35. The method of any one of claims 27 to 34, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

36. The method of any one of claims 27 to 35, wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

37. The method of any one of claims 27 to 36, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C.

38. The method of any one of claims 27 to 37, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000.

39. The method of any one of claims 27 to 38, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher.

40. The method of any one of claims 27 to 39, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3-propanediol diglycidyl ether, 1 ,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, poly functional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a poly functional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

41. The method of any one of claims 27 to 40, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

42. The method of any one of claims 27 to 41, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

43. The method of any one of claims 27 to 42, further comprising mixing the intumescent component with a polymer.

44. The method of claim 43, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

45. The method of claim 43 or 44, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobomyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

46. The method of any one of claims 43 to 45, wherein the polymer comprises a solid thermoplastic resin.

47. The method of any one of claims 43 to 46, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

48. The method of any one of claims 27 to 47, wherein the composition is free of solvents other than the monomer mixture.

49. The method of any one of claims 27 to 48, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

50. The method of any one of claims 27 to 49, wherein the reaction product constitutes from 2 % to 60 % of the intumescent coating composition by weight.

51. The method of any one of claims 27 to 50, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

52. The method of any one of claims 27 to 51, further comprising mixing the composition with a peroxide initiator.

53. The method of any one of claims 27 to 52, further comprising mixing the composition with an amine accelerator.

54. A method of coating a substrate with an intumescent coating, the method comprising: mixing a liquid intumescent coating composition with an initiator and an amine accelerator to produce an activated coating composition, the liquid intumescent coating composition comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component; applying the activated coating composition onto the substrate; and allowing the activated coating composition to cure under ambient conditions into a solid state to form the intumescent coating.

55. The method of claim 54, wherein the liquid intumescent coating composition cures via free radical polymerization.

56. The method of claim 54 or 55, wherein the epoxy component and the mono-functional carboxylic acid are dissolved in the monomer mixture.

57. The method of any one of claims 54 to 56, wherein the reaction product is dissolved in the monomer mixture.

58. The method of any one of claims 54 to 57, wherein the mono-functional carboxylic acid comprises butanoic (butyric) acid (CH3(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)3COOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)5COOH), octanoic (caprylic) acid (CH3(CH2)6COOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)IOCOOH), tridecanoic acid (CH3(CH2)IICOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH (CH2)ISCOOH), octadecanoic (stearic) acid (CH (CH2)i6COOH), nonadecanoic acid (CH (CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)ISCOOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH2)i4COOH).

59. The method of any one of claims 54 to 58, wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

60. The method of any one of claims 54 to 59, wherein the epoxy component comprises an epoxy resin comprising two or more epoxide groups.

61. The method of any one of claims 54 to 60, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C.

62. The method of any one of claims 54 to 61, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000.

63. The method of any one of claims 54 to 62, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher.

64. The method of any one of claims 54 to 63, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3 -propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, polyfunctional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

65. The method of any one of claims 54 to 64, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

66. The method of any one of claims 54 to 65, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

67. The method of any one of claims 54 to 66, wherein the liquid intumescent coating composition further comprises a polymer.

68. The method of claim 67, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

69. The method of claim 67 or 68, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobomyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

70. The method of any one of claims 67 to 69, wherein the polymer comprises a solid thermoplastic resin.

71. The method of any one of claims 67 to 70, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

72. The method of any one of claims 54 to 71, wherein the initiator comprises an organic peroxide.

73. The method of any one of claims 54 to 72, wherein the composition is free of solvents other than the monomer mixture.

74. The method of any one of claims 54 to 73, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

75. The method of any one of claims 54 to 74, wherein the reaction product constitutes from 2 % to 60 % of the intumescent coating composition by weight.

76. The method of any one of claims 54 to 75, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.

77. The method of any one of claims 54 to 76, wherein the activated coating composition is cured in 60 minutes or less at a temperature of 25 °C or less.

78. The method of any one of claims 54 to 77, wherein less than 5 % by weight of volatile components is lost from the coating composition by evaporation during the curing.

79. The method of any one of claims 54 to 78, wherein the intumescent coating has a Shore D hardness of 45 to 90 measured 24 hours after application.

80. A kit for applying an intumescent coating to a substrate, the kit comprising: a first part comprising a resin system comprising: a reaction product of: an epoxy component; and a mono-functional carboxylic acid having a chain length of 6 to 30 carbons; a monomer mixture comprising at least one ethylenically unsaturated monomer; and an intumescent component; and a second part comprising a peroxide initiator and an amine accelerator.

81. The kit of claim 80, wherein the epoxy component comprises an epoxy resin that is solid at a temperature of 20 °C.

82. The kit of claim 80 or 81, wherein the epoxy component comprises an epoxy resin having a molecular weight in a range from 500 to 5000.

83. The kit of any one of claims 80 to 82, wherein the epoxy component comprises an epoxy resin having a glass transition temperature of 20 °C or higher.

84. The kit of any one of claims 80 to 83, wherein the epoxy component comprises an epoxy resin comprising butyl diglycidyl ether, neopentyl glycol diglycidyl ether, 1,3 -propanediol diglycidyl ether, 1,4 - butanediol diglycidyl ether, 1,6 - hexanediol diglycidyl ether, bisphenol diglycidyl ether, dihydroxy naphthalene diglycidyl ether, dihydroxy anthracene diglycidyl ether, triglycidyl isocyanurate, tetraglycidyl glycoluril, a polyfunctional epoxy resin having a glycidyl amino group derived from metaxylylene diamine, poly functional epoxy resin having a glycidyl amino group derived from l,3-bis(aminomethyl) cyclohexane, a polyfunctional epoxy resin having a glycidyl amino group derived from diaminodiphenylmethane, a polyfunctional epoxy resin having a glycidyl amino group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from paraaminophenol, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

85. The kit of any one of claims 80 to 84, wherein the epoxy component comprises an epoxy resin comprising a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A, a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol F, a polyfunctional epoxy resin having a glycidyloxy group derived from phenol novolac, a polyfunctional epoxy resin having two or more glycidyloxy groups derived from resorcinol, or a combination of two or more thereof.

86. The kit of any one of claims 80 to 85, wherein the epoxy component comprises a polyfunctional epoxy resin having a glycidyloxy group derived from bisphenol A.

87. The kit of any one of claims 80 to 86, further comprising an epoxide-ring-opening catalyst.

88. The kit of claim 87, wherein the catalyst comprises pyridine, isoquinoline, quinoline, N,N-dimethylcyclohexylamine, tributylamine, N-ethylmorpholine, dimethylaniline, octyldimethyl amine, n,n-dimethylbenzylamine, dodecyl dimethyl benzylamine, tetramethyl guanidine, triethylene diamine, quaternary ammonium salt, quaternary phosphonium salt, dodecyltrimethylammonium bromide, benzyltrimethylammonium bromide, triphenylethyl phosphonium bromide, 1 -methyl imidazole, 1,2-dimethyl imidazole, 2-methyl imidazole, 2-ethyl imidazole, 1-ethyl imidazole, 1,3-disubstituted imidazolium salt, 1,3 -di substituted imidazolium bicarbonate, 1,3-disubstituted imidazolium-2-carboxylate, 1,3-disubstituted imidazolium acetate, halide of Al, B, Be, Ti, Zr, Zn, Sn, or Fe (III), zinc acetoacetonate, zinc octoate, zinc acetate, boron trifluoride, trimethoxy boroxine, a chromium-based catalyst, or a combination of two or more thereof.

89. The kit of claim 87 or 88, wherein the mono-functional carboxylic acid comprises butanoic (butyric) acid (CHs(CH2)2COOH), pentanoic (valeric) acid (CH3(CH2)sCOOH), hexanoic (caproic) acid (CH3(CH2)4COOH), heptanoic (enanthic) acid (CH3(CH2)sCOOH), octanoic (caprylic) acid (CH3(CH2)6COOH), nonanoic (pelargoic) acid (CH3(CH2)?COOH), decanoic (capric) acid (CH3(CH2)sCOOH), undecanoic acid (CH3(CH2)9COOH), dodecanoic (lauric) acid (CH3(CH2)ioCOOH), tridecanoic acid (CH3(CH2)nCOOH), tetradecanoic (myristic) acid (CH3(CH2)i2COOH), pentadecanoic acid (CH3(CH2)i3COOH), hexadecanoic (palmitic) acid (CH3(CH2)i4COOH), heptadecanoic (margaric) acid (CH3(CH2)ISCOOH), octadecanoic (stearic) acid (CH3(CH2)ieCOOH), nonadecanoic acid (CH3(CH2)I?COOH), icosanoic (arachidic) acid (CH3(CH2)i8COOH), or a combination of two or more thereof, optionally wherein the mono-functional carboxylic acid comprises hexadecanoic (palmitic) acid (CH3(CH₂)i4COOH).

90. The kit of any one of claims 87 to 89, wherein the catalyst comprises 1,2-dimethyl imidazole.

91. The kit of any one of claims 80 to 90, wherein the ethylenically unsaturated monomer comprises wherein the ethylenically unsaturated monomer comprises (meth)acrylic acid, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, decyl acrylate, lauryl acrylate, lauryl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, isodecyl methacrylate, or a combination of two or more thereof.

92. The kit of any one of claims 80 to 91, wherein the resin system further comprises a polymer.

93. The kit of claim 92, wherein the polymer comprises at least one of a homopolymer, copolymer, or terpolymer of a methacrylic resin, optionally wherein the polymer comprises a (meth)acrylate copolymer.

94. The kit of claim 92 or 93, wherein the polymer comprises a reaction product of at least one of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate and 2-ethylhexyl acrylate, isobomyl methacrylate, isobornyl acrylate, benzyl methacrylate, and 2-octyl acrylate.

95. The kit of any one of claims 92 to 94, wherein the polymer comprises a solid thermoplastic resin.

96. The kit of any one of claims 92 to 95, wherein the polymer comprises a reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidene chloride and vinyl versatate esters.

97. The kit of any one of claims 80 to 96, wherein the composition is free of solvents other than the monomer mixture.

98. The kit of any one of claims 80 to 97, wherein the monomer mixture constitutes from 30 % to 90 % of the resin system by weight.

99. The kit of any one of claims 80 to 98, wherein the reaction product constitutes from 2 % to 60 % of the intumescent coating composition by weight.

100. The kit of any one of claims 80 to 99, wherein the intumescent component comprises an acid source, a carbon source, and a gas source providing an expansion gas upon thermal decomposition.