US5989706A
Expired / Lapsed
US
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Thermally-protective intumescent coating system and method
Assignee: Battelle Memorial Institute Inc
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Filing: 1998-09-30
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Granted: 1999-11-23
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Expires: 2018-09-30
Abstract
Abstract An intumescent coating system and method therefor is disclosed for thermally protecting a substrate having a surface exposed to fire conditions. The coating system of the present invention is provided as having a having a first film layer which forms a rigid carbonific char foam having toughness and rigidity, and a second film layer which forms an insulative carbonific char foam having 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. In providing two foam components, one protecting the substrate from breakthrough and direct exposure to the fire conditions, and the other insulating the substrate to protect it from conductive, radiant, and/or convective heating by the fire conditions, the present invention affords a capability to offer flame retardancy at film thicknesses of 1.27 mm (50 mils) or less.
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 17:57
CPC Classifications
C; C09; C09K; C09K21/00; C09D; C09D5/00; C09D5/18; C09D5/185; Y; Y10; Y10T; Y10T428/00; Y10T428/27; Y10T428/273; Y10T428/31504; Y10T428/31511
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
130 words
An intumescent coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising: (a) a first coating layer coated on the 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; and wherein said intumescent coating system has a thickness of 1.27 mm (50 mils) or less.
Claim 2
Dependent Claim
130 words
An intumescent coating system for thermally protecting a substrate having a surface exposed to fire conditions comprising: (a) a first coating layer coated on the 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; and wherein said intumescent coating system has a thickness of 1.27 mm (50 mils) or less.
Claim 3
Dependent Claim
30 words
The intumescent 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
27 words
The intumescent coating system of claim 1 wherein upon exposure to fire conditions said rigid carbonific char foam is harder relative to said insulative carbonific char foam.
Claim 5
Dependent Claim
36 words
The intumescent coating system of claim 1 wherein, upon exposure to fire conditions, said insulative carbonific char foam comprises a lower density foam exhibiting has a lower thermal conductivity relative to said rigid carbonific char foam.
Claim 6
Dependent Claim
69 words
The intumescent 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, said insulative carbonific char foam forming under said second rigid carbonific char foam.
Claim 7
Dependent Claim
84 words
The intumescent 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, said insulative carbonific char foam forming under said carbonific char foam blend.
Claim 8
Independent Claim
155 words
A method for thermally protecting a 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; and wherein said first and second film layers comprise an intumescent coating system having a thickness of 1.27 mm (50 mils) or less.
Claim 9
Independent Claim
155 words
A method for thermally protecting a 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; and wherein said first and second film layers comprise an intumescent coating system having a thickness of 1.27 mm (50 mils) or less.
Claim 10
Dependent Claim
28 words
The method of claim 7 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 11
Dependent Claim
53 words
The method of claim 7 wherein said rigid carbonific char foam has a density of between about 0.5 g/cm 3 and less than about 1.0 g/cm 3 , and said insulative carbonific char foam has a density of between greater than about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 12
Dependent Claim
80 words
The method of claim 7 further comprising the steps of: (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, said insulative carbonific char foam forming under said second rigid carbonific char foam.
Claim 13
Dependent Claim
103 words
The method of claim 7 further comprising the steps: (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, said insulative carbonific char foam forming under said carbonific char foam blend.
Claim 14
Dependent Claim
10 words
The substrate coated according to the method of claim 7.
Claim 15
Dependent Claim
10 words
The substrate coated according to the method of claim 10.
Claim 16
Dependent Claim
10 words
The substrate coated according to the method of claim 11.
Claim 17
Dependent Claim
55 words
The intumescent coating system of claim 1 wherein said rigid carbonific char foam has a density of between about 0.5 g/cm 3 and less than about 1.0 g/cm 3 , and said insulative carbonific char foam has a density of between greater than about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 18
Dependent Claim
56 words
The intumescent 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 insulative carbonific char foam.
Claim 19
Dependent Claim
58 words
The intumescent coating system of claim 5 wherein said first and second rigid carbonific char foams have a density of between about 0.5 g/cm 3 and less than about 1.0 g/cm 3 , and said insulative carbonific char foam has a density of between greater than about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
Claim 20
Dependent Claim
56 words
The method of claim 10 wherein said first and second rigid carbonific char foams have a density of between about 0.5 g/cm 3 and less than about 1.0 g/cm 3 , and said insulative carbonific char foam has a density of between greater than about 0.01 g/cm 3 and less than about 0.5 g/cm 3 .
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 7.5 Years (Year 8) | 2006-11-22 | 2007-05-24 | 2007-11-23 | $3760.00 | Window Closed / Lapsed |
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