Patent FR782179A successfully refreshed from Google Patents.
US5487946A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermally-protective intumescent coating
Assignee: Battelle Memorial Institute Inc
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Filing: 1994-08-02
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Granted: 1996-01-30
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Expires: 2014-08-02
Abstract
Abstract An intumescent coating system and method therefor is disclosed for thermally protecting a substrate having a surface exposed to a flame environment. The coating system of the present invention is provided as having a having a first component which forms a rigid carbonific char foam having toughness and rigidity, and a second component which forms an insulative carbonific char foam having a density about half the density of the rigid carbonific foam to give insulation properties. The two foam components may be separately provided in a laminate-type arrangement as, respectively, an inner coating layer coated and cured on the surface of the substrate to form an inner film layer, and an outer coating layer coated and cured on the inner film layer to form an outer film layer. Alternatively, the two foams may be provided as being formed from components blended to comprise a single coating layer which is coated and cured on the surface of the substrate to form a film layer. In providing two foam components, one protecting the substrate from breakthrough and direct exposure to the flame environment, and the other insulating the substrate to protect it from conductive, radiant, and/or convective heating by the flame environment, the present invention affords a capability to offer flame retardancy at film thicknesses of less than 50 mils.
Inventors
- 👤 Vincent D. McGinniss
- 👤 Richard J. Dick
- 👤 Robert E. Russell, III
- 👤 Stephen D. Rogers
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 23:28
CPC Classifications
C; C09; C09D; C09D5/00; C09D5/18; C09D5/185; C09K; C09K21/00; C09K21/06; Y; Y10; Y10S; Y10S428/00; Y10S428/92; Y10S428/921; Y10T; Y10T428/00; Y10T428/27; Y10T428/273; Y10T428/31504; Y10T428/31511; Y10T428/31652; Y10T428/31663
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
166 words
A coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising: (a) a first coating layer coated on said surface of said substrate and cured thereon to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; and (b) a second coating layer coated on said first film layer and cured thereon to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions; and wherein said coating system has a thickness of less than 50 mils.
Claim 2
Dependent Claim
166 words
A coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising: (a) a first coating layer coated on said surface of said substrate and cured thereon to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; and (b) a second coating layer coated on said first film layer and cured thereon to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions; and wherein said coating system has a thickness of less than 50 mils.
Claim 3
Dependent Claim
29 words
The coating system of claim 1 wherein said insulative carbonific char foam has a density of between about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 4
Dependent Claim
105 words
The coating system of claim 1 wherein said second coating layer comprises: a curable binder; a char promoter having hydroxyl groups; a dehydrating agent which is thermally decomposable to form an acid catalyst, said char promoter dehydrating in the presence of said acid catalyst to form an intermediate species which intermediate species is thermally decomposable to form said second carbonific char; and a spumific which is thermally decomposable to release a nonflammable, inert gas for foaming said second carbonific char into said insulative carbonific char foam, said spumific having a decomposition temperature higher than the decomposition temperatures of said dehydrating agent and said intermediate species.
Claim 5
Dependent Claim
14 words
The coating system of claim 3 wherein said char promoter is a polyhydric alcohol.
Claim 6
Dependent Claim
21 words
The coating system of claim 4 wherein said alcohol is selected from the group consisting of pentaerythritol, dipentaerythritol and mixtures thereof.
Claim 7
Dependent Claim
23 words
The coating system of claim 3 wherein said dehydrating agent is an acid precursor which is thermally decomposable to form said acid catalyst.
Claim 8
Dependent Claim
27 words
The coating system of claim 6 wherein said acid precursor is selected from the group consisting of ammonium phosphate, ammonium polyphosphate, phosphites, organophosphite esters and mixtures thereof.
Claim 9
Dependent Claim
15 words
The coating system of claim 3 wherein said spumific is a dicyandiamide or an azodicarbonamide.
Claim 10
Dependent Claim
27 words
The intumescent coating of claim 3 wherein said binder is selected from the group consisting of an epoxy, a polysulfide, a polysiloxane, a polysilarylene, and mixtures thereof.
Claim 11
Dependent Claim
18 words
The coating system of claim 1 wherein said first coating layer comprises an epoxy resin and a polysulfide.
Claim 12
Dependent Claim
81 words
The coating system of claim 1 further comprising a third coating layer coated on said second film layer and cured thereon to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a second rigid carbonific char foam having a density about twice the density of said insulative carbonific char foam, said insulative carbonific char foam forming under said second rigid carbonific char foam.
Claim 13
Dependent Claim
29 words
The coating system of claim 11 wherein said insulative carbonific char foam has a density of between about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 14
Dependent Claim
18 words
The coating system of claim 11 wherein said third coating layer comprises an epoxy resin and a polysulfide.
Claim 15
Dependent Claim
106 words
The coating system of claim 1 further comprising a third coating layer formulated as a blend of said first and said second coating layers, said third coating layer being coated on said second film layer and cured thereon to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a carbonific char foam blend having a first foam component and a second foam component having a density of about half the density of said first foam component, said insulative carbonific char foam forming under said carbonific char foam blend.
Claim 16
Dependent Claim
28 words
The coating system of claim 14 wherein said second foam component has a density of between about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 17
Dependent Claim
189 words
A substrate coated according to method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam (c) coating a second coating layer on said first film layer; and (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions: wherein said coating layers have a thickness of less than 50 mils.
Claim 18
Dependent Claim
189 words
A substrate coated according to method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam (c) coating a second coating layer on said first film layer; and (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions: wherein said coating layers have a thickness of less than 50 mils.
Claim 19
Dependent Claim
271 words
A substrate coated according to method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; (c) coating a second coating layer on said first film layer; (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire condition; (e) coating a third coating layer on said second film layer, and (f) curing said third coating layer on said second coating layer to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a second rigid carbonific char foam having a density about twice the density of said insulative carbonific char foam, said insulative carbonific char foam forming under said second rigid carbonific char foam: wherein said coating layer have a thickness of less than 50 mils.
Claim 20
Dependent Claim
271 words
A substrate coated according to method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; (c) coating a second coating layer on said first film layer; (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire condition; (e) coating a third coating layer on said second film layer, and (f) curing said third coating layer on said second coating layer to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a second rigid carbonific char foam having a density about twice the density of said insulative carbonific char foam, said insulative carbonific char foam forming under said second rigid carbonific char foam: wherein said coating layer have a thickness of less than 50 mils.
Claim 21
Dependent Claim
296 words
A substrate coated according to a method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; (c) coating a second coating layer on said first film layer; (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions; (e) coating a third coating layer on said second film layer, said third coating layer formulated as a blend of said first and said second coating layers; and (f) curing said third coating layer on said second coating layer to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a carbonific char foam blend having a first foam component, and a second foam component having a density about half the foam density of said first foam component, said insulative carbonific char foam forming under said carbonific char foam blend wherein said coating layers have a thickness of less than 50 mils.
Claim 22
Dependent Claim
296 words
A substrate coated according to a method for thermally protecting said substrate having a surface exposed to fire conditions comprising the steps of: (a) coating said surface of said substrate with a first coating layer, (b) curing said first coating layer on said surface of said substrate to form a first film layer which layer is thermally decomposable upon exposure to said fire conditions to form a first carbonific char which char intumesces to form a first rigid carbonific char foam; (c) coating a second coating layer on said first film layer; (d) curing said second coating layer on said first coating layer to form a second film layer which layer is thermally decomposable upon exposure to said fire conditions to form a second carbonific char which char intumesces to form an insulative carbonific char foam having a density about half the density height of said first rigid carbonific char foam, said first rigid carbonific char foam forming where said insulative carbonific char foam has broken through to expose said first film layer to said fire conditions; (e) coating a third coating layer on said second film layer, said third coating layer formulated as a blend of said first and said second coating layers; and (f) curing said third coating layer on said second coating layer to form a third film layer which layer is thermally decomposable upon exposure to said fire conditions to form a third carbonific char which char intumesces to form a carbonific char foam blend having a first foam component, and a second foam component having a density about half the foam density of said first foam component, said insulative carbonific char foam forming under said carbonific char foam blend wherein said coating layers have a thickness of less than 50 mils.
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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) | 1999-01-29 | 1999-07-31 | 2000-01-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-01-29 | 2003-07-31 | 2004-01-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-01-29 | 2007-07-31 | 2008-01-30 | $7700.00 | Window Closed / Lapsed |