US4529467A
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US
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Fire protective intumescent mastic composition and method employing same
Assignee: PPG Industries Ohio Inc
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Filing: 1983-10-25
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Granted: 1985-07-16
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Expires: 2003-10-25
Abstract
Abstract An intumescent curable composition has as its principal constituents an epoxy resin; a curing agent; and an additive component which is composed of a mixture of materials which provide a source of phosphorus, zinc, boron and an expansion gas. The aforesaid composition is capable of forming a carbonaceous char upon exposure to heat or flame.
Inventors
- 👤 Thomas A. Ward
- 👤 Stanley T. Greer
- 👤 William G. Boberski
- 👤 Jerome A. Seiner
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 19:07
CPC Classifications
C; C09; C09K; C09K3/00; C09K3/10; C08; C08J; C08J9/00; C08J9/04; C08J9/06; C09D; C09D5/00; C09D5/18; C09D5/185; C09K21/00; C09K21/14; C09K2003/1034; C09K2003/1037; C09K2003/1078; C09K2200/00; C09K2200/02; C09K2200/0217; C09K2200/0234; C09K2200/0239; C09K2200/0243; C09K2200/0273; C09K2200/04; C09K2200/0458; C09K2200/0476; C09K2200/06; C09K2200/0645; C09K2200/0647; Y; Y10; Y10S; Y10S260/00; Y10S260/24; Y10S428/00; Y10S428/913; Y10S428/92; Y10S428/921; Y10T; Y10T442/00; Y10T442/20; Y10T442/2631; Y10T442/2648
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
105 words
A process for protecting a substrate from fire and excessive heat comprising: I. applying to the surface of a substrate a coating of a char-forming intumescent curable composition comprising: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (a) phosphorus, (b) zinc, (c) boron, and (d) an expansion gas upon thermal decomposition; said composition being capable of forming a carbonaceous char upon exposure to heat or flame; II. overlaying the intumescent composition with a mesh member; and III. allowing the intumescent composition to cure.
Claim 2
Dependent Claim
105 words
A process for protecting a substrate from fire and excessive heat comprising: I. applying to the surface of a substrate a coating of a char-forming intumescent curable composition comprising: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (a) phosphorus, (b) zinc, (c) boron, and (d) an expansion gas upon thermal decomposition; said composition being capable of forming a carbonaceous char upon exposure to heat or flame; II. overlaying the intumescent composition with a mesh member; and III. allowing the intumescent composition to cure.
Claim 3
Dependent Claim
17 words
The process of claim 1 wherein the additive component of the composition additionally contains a reinforcing filler.
Claim 4
Dependent Claim
30 words
The process of claim 2, additionally including the step of overlying the mesh member with a coating of said intumescent composition so as to substantially encapsulate the entire mesh member.
Claim 5
Dependent Claim
14 words
The process of claim 2 wherein the epoxy resin is an aromatic epoxy resin.
Claim 6
Dependent Claim
12 words
The process of claim 2 wherein the curing agent is a polyamine.
Claim 7
Dependent Claim
40 words
The process of claim 2 wherein the material adapted to provide a source of phosphorus is an ammonium polyphosphate represented by the formula (NH 4 ) n+2 P n O 3n+1 wherein n is an integer of at least 2.
Claim 8
Dependent Claim
11 words
The process of claim 2 wherein the reinforcing filler is Wollastonite.
Claim 9
Independent Claim
165 words
A method of reducing the rate of temperature rise in a substrate when it is subjected to fire conditions, which comprises applying to the surface of the substrate a curable composition which when exposed to fire conditions intumesces, characterized in that said composition comprises: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (i) phosphorus, (ii) zinc, (iii) boron, and (iv) an expansion gas upon thermal decomposition; said composition being adapted to provide a carbonaceous char when exposed to fire conditions retaining its integral structure and adhering to the substrate without external reinforcement, with the proviso that when applied onto a 10W29 steel beam at a thickness of about 0.60 inches and subjected to Underwriter's Laboratories test, UL-263, the char that is formed is capable of maintaining the steel at a temperature below 1000° F. for a period of at least about 2 hours.
Claim 10
Independent Claim
165 words
A method of reducing the rate of temperature rise in a substrate when it is subjected to fire conditions, which comprises applying to the surface of the substrate a curable composition which when exposed to fire conditions intumesces, characterized in that said composition comprises: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (i) phosphorus, (ii) zinc, (iii) boron, and (iv) an expansion gas upon thermal decomposition; said composition being adapted to provide a carbonaceous char when exposed to fire conditions retaining its integral structure and adhering to the substrate without external reinforcement, with the proviso that when applied onto a 10W29 steel beam at a thickness of about 0.60 inches and subjected to Underwriter's Laboratories test, UL-263, the char that is formed is capable of maintaining the steel at a temperature below 1000° F. for a period of at least about 2 hours.
Claim 11
Dependent Claim
13 words
The method of claim 8 wherein the substrate is a structural steel column.
Claim 12
Dependent Claim
63 words
An intumescent, curable composition, comprising (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (a) phosphorus; (b) zinc; (c) boron; and (d) expansion gas upon thermal decomposition; said composition being capable of forming a carbonaceous char upon exposure to heat or flame.
Claim 13
Dependent Claim
63 words
An intumescent, curable composition, comprising (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (a) phosphorus; (b) zinc; (c) boron; and (d) expansion gas upon thermal decomposition; said composition being capable of forming a carbonaceous char upon exposure to heat or flame.
Claim 14
Dependent Claim
14 words
The composition of claim 10 wherein the additive component additionally contains a reinforcing filler.
Claim 15
Dependent Claim
14 words
The composition of claim 11 wherein the epoxy resin is an aromatic epoxy resin.
Claim 16
Dependent Claim
19 words
The composition of claim 12 wherein the aromatic epoxy resin is a polyglycidyl ether of a polyhydric aromatic alcohol.
Claim 17
Dependent Claim
15 words
The composition of claim 13 wherein the epoxy resin is the diglycidyl ether of 4,4'-isopropylidenediphenol.
Claim 18
Dependent Claim
12 words
The composition of claim 11 wherein the curing agent is a polyamine.
Claim 19
Dependent Claim
22 words
The composition of claim 15 wherein the polyamine curing agent is the reaction product of an amine and an aliphatic fatty acid.
Claim 20
Dependent Claim
40 words
The composition of claim 11 wherein the material adapted to provide a source of phosphorus is an ammonium polyphosphate represented by the formula (NH 4 ) n+2 P n O 3n+1 wherein n is an integer of at least 2.
Claim 21
Dependent Claim
14 words
The composition of claim 17 wherein n is an integer of at least 50.
Claim 22
Dependent Claim
19 words
The composition of claim 11 wherein the material adapted to provide a source of phosphorus is a phosphorus-containing amide.
Claim 23
Dependent Claim
20 words
The composition of claim 11 wherein the material adapted to provide a source of expansion gas is a nitrogen-containing material.
Claim 24
Dependent Claim
12 words
The composition of claim 20 wherein the expansion gas-providing material is melamine.
Claim 25
Dependent Claim
29 words
The composition of claim 11 wherein the material adapted to provide a source of zinc is selected from the group containing of zinc oxide, zinc borate, and zinc phosphate.
Claim 26
Dependent Claim
29 words
The composition of claim 11 wherein the material adapted to provide a source of boron is selected from the group consisting of boric acid, ammonium borate, and sodium borate.
Claim 27
Dependent Claim
15 words
The composition of claim 11 wherein the reinforcing filler is in fibrous or platelet form.
Claim 28
Dependent Claim
11 words
The composition of claim 24 wherein the reinforcing filler is Wollastonite.
Claim 29
Dependent Claim
43 words
The composition of claim 11 as a two package system with the epoxy resin in one package, the curing agent in a second package and the additive component in either the epoxy resin package or the curing agent package, or in both packages.
Claim 30
Dependent Claim
19 words
The composition of claim 11 as a one package system wherein the curing agent is a latent curing agent.
Claim 31
Dependent Claim
159 words
A substrate which demonstrates a reduced rate of temperature rise when it is subjected to fire conditions, characterized by having applied on the substrate surface a curable composition which when exposed to fire conditions intumesces, said composition, comprising: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (i) phosphorus, (ii) zinc, (iii) boron, and (iv) an expansion gas upon thermal decomposition; said composition being adapted to provide a carbonaceous char when exposed to fire conditions retaining its integral structure and adhering to the substrate without external reinforcement, with the proviso that when applied onto a 10W49 steel beam at a thickness of about 0.60 inches and subjected to Underwriter's Laboratories test, UL-263, the char that is formed is capable of maintaining the steel at a temperature below 1000° F. for a period of at least about 2 hours.
Claim 32
Dependent Claim
159 words
A substrate which demonstrates a reduced rate of temperature rise when it is subjected to fire conditions, characterized by having applied on the substrate surface a curable composition which when exposed to fire conditions intumesces, said composition, comprising: (a) an epoxy resin; (b) a curing agent adapted to cure said epoxy resin; and (c) an additive component, comprising a mixture of materials adapted to provide a source of (i) phosphorus, (ii) zinc, (iii) boron, and (iv) an expansion gas upon thermal decomposition; said composition being adapted to provide a carbonaceous char when exposed to fire conditions retaining its integral structure and adhering to the substrate without external reinforcement, with the proviso that when applied onto a 10W49 steel beam at a thickness of about 0.60 inches and subjected to Underwriter's Laboratories test, UL-263, the char that is formed is capable of maintaining the steel at a temperature below 1000° F. for a period of at least about 2 hours.
Claim 33
Dependent Claim
11 words
The substrate of claim 28 which is a structural steel column.
Claim 34
Dependent Claim
17 words
The substrate of claim 29 wherein the additive component of the composition additionally contains a reinforcing filler.
Claim 35
Dependent Claim
13 words
The substrate of claim 29 wherein the composition additionally contains a reinforcing filler.
Claim 36
Dependent Claim
14 words
The substrate of claim 29 wherein the epoxy resin is an aromatic epoxy resin.
Claim 37
Dependent Claim
19 words
The substrate of claim 32 wherein the aromatic epoxy resin is a polyglycidyl ether of a polyhydric aromatic alcohol.
Claim 38
Dependent Claim
12 words
The substrate of claim 29 wherein the curing agent is a polyamine.
Claim 39
Dependent Claim
22 words
The substrate of claim 34 wherein the polyamine curing agent is the reaction product of an amine and an aliphatic fatty acid.
Claim 40
Dependent Claim
40 words
The substrate of claim 29 wherein the material adapted to provide a source of phosphorus is an ammonium polyphosphate represented by the formula (NH 4 ) n+2 P -n O -3n+1 wherein n is an integer of at least 2.
Claim 41
Dependent Claim
14 words
The substrate of claim 36 wherein n is an integer of at least 50.
Claim 42
Dependent Claim
19 words
The substrate of claim 29 wherein the material adapted to provide a source of phosphorus is a phosphorus-containing amide.
Claim 43
Dependent Claim
20 words
The substrate of claim 29 wherein the material adapted to provide a source of expansion gas is a nitrogen-containing material.
Claim 44
Dependent Claim
12 words
The substrate of claim 39 wherein the expansion gas-providing material is melamine.
Claim 45
Dependent Claim
29 words
The substrate of claim 29 wherein the material adapted to provide a source of zinc is selected from the group consisting of zinc oxide, zinc borate, and zinc phosphate.
Claim 46
Dependent Claim
29 words
The substrate of claim 29 wherein the material adapted to provide a source of boron is selected from the group consisting of boric acid, ammonium borate, and sodium borate.
Claim 47
Dependent Claim
15 words
The substrate of claim 29 wherein the reinforcing filler is in fibrous or platelet form.
Claim 48
Dependent Claim
11 words
The substrate of claim 43 wherein the reinforcing filler is Wollastonite.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-07-15 | 1989-01-14 | 1989-07-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-07-15 | 1993-01-14 | 1993-07-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-07-15 | 1997-01-14 | 1997-07-16 | $7700.00 | Window Closed / Lapsed |