Composition forming an insulating layer and use of said composition

Abstract

The invention relates to a composition forming an insulating layer, which composition contains a binder, which is based on a compound having electron-deficient carbon multiple bonds and a carbanion-forming compound. By means of the composition according to the invention, the expansion rate of which is relatively high, coatings having the layer thickness required for the particular fire resistance time can be applied easily and quickly, wherein the layer thickness can be reduced to a minimum and nevertheless a great insulating effect can be achieved. The composition according to the invention is suitable especially for fire protection, in particular as a coating of steel components, such as supports, beams and truss members, for increasing the fire resistance time.

Claims

1. A coating composition comprising: (a) an ingredient A that contains a polyfunctional Michael acceptor that has at least two electron-deficient carbon multiple bonds per molecule as functional Michael acceptor groups, wherein the functional Michael acceptor groups have the structure (III): ##STR00003## in which R.sup.1, R.sup.2 and R.sup.3 are each hydrogen; Y represents OR.sup.5, wherein R.sup.5 is hydrogen or a linear, branched, or cyclical, optionally substituted alky group; (b) an ingredient B that contains a polyfunctional Michael donor that has at least two C, H acid groups per molecule as functional Michael donor groups, wherein the functional Michael donor groups are -ketoesters; (c) an ingredient C that contains an additive that forms an insulation layer, wherein the additive forming the insulation layer is a mixture comprising at least one dehydrogenation catalyst and at least one propellant; and (d) a catalyst for the Michael addition reaction, wherein the coating composition forms an insulation layer upon exposure to heat.

2. The composition of claim 1, wherein each functional Michael acceptor group is attached by means of one or more of R.sup.1, R.sup.2, R.sup.3, or R.sup.5 to another functional Michael acceptor group, which can be identical or different, or directly attached to a backbone.

3. The composition of claim 2, wherein the functional Michael acceptor groups are bonded by means of R.sup.5 to a polyol compound, an oligomer or polymer.

4. The composition of claim 3, wherein the functional Michael acceptor groups or the functional Michael donor groups are each independently bonded to a polyol compound that is selected from the group consisting of pentaerythritol, trimethylolpropane, ethylene glycol and polyethylene glycols, propylene glycols and polypropylene glycols.

5. The composition of claim 1, wherein the composition has a reactive equivalent ratio in the range of 0.1:1 to 10:1.

6. The composition of claim 1, wherein the additive forming the insulation layer further comprises at least one carbon supplier.

7. The composition of claim 6, wherein the additive forming the insulation layer further comprises an ash crust stabilizer.

8. The composition of claim 1, wherein the composition also contains organic and/or inorganic additives.

9. The composition of claim 1, wherein the composition is packaged as a two-component or multi-component system.

10. The composition of claim 9, wherein the ingredient C is contained in a single component of the two-component or multi-component system; or wherein the ingredient C is contained in multiple components of the two-component or multi-component system in the form of a complete mixture or in the form of individual components.

11. The composition of claim 7, wherein the composition is packaged as a two-component or multi-component system, and wherein the ash crust stabilizer is contained in one component of the two-component or multi-component system, or wherein the ash crust stabilizer is divided among the components of the two-component or multi-component system.

12. A coating comprising the composition of claim 1.

13. The coating of claim 12, wherein the coating is for steel construction elements.

14. The coating of claim 12, wherein the coating is for non-metallic components.

15. The coating of claim 12, wherein the coating is a fire protection coating.

Description

EXEMPLARY EMBODIMENTS

(1) The ingredients listed below are used for the production of the compounds claimed by the invention that form an insulation layer. The individual components are always combined and homogenized by means of a dissolver. For use, these mixtures are then mixed and applied either before spraying or preferably during spraying.

(2) The curing behavior of the composition was observed, as well as the intumescence factor and the relative ash crust stability. For this purpose, the compounds were each placed in a round Teflon mold 2 mm deep and 48 mm in diameter.

(3) The curing time thereby equals the time after which the specimens were cured and could be removed from the Teflon mold.

(4) For the determination of the intumescence factor and the relative ash crust stability, a muffle furnace was preheated to 600 C. Multiple measurements of the specimen thickness were taken with a vernier caliper and the average value h.sub.M was calculated. The specimens were then each placed in a cylindrical steel mold and heated for 30 minutes in the muffle furnace. After cooling to room temperature, the height of the foam h.sub.E1 was first measured nondestructively (average value of multiple measurements). The intumescence factor I is calculated as follows:
I=h.sub.E1:h.sub.MIntumescence factor I:

(5) Then a defined weight (m=105 g) was allowed to drop from a defined height (h=100 mm) into the cylindrical steel mold and onto the foam, and after this partly destructive action the remaining phone height h.sub.E2 was determined. The relative ash crust stability was calculated as follows:
AKS=h.sub.E2:h.sub.E1Relative ash crust stability (AKS):

(6) For the following examples 1 to 8 and the comparative examples 2 and 3, the following composition was used as ingredient C and the composition was added in the indicated quantities:

(7) Ingredient C:

(8) TABLE-US-00001 Ingredient Quantity [g] Pentaerythrite 8.7 Melamine 8.7 Ammonium polyphosphate 16.6 Titanium dioxide 7.9

EXAMPLE 1

(9) Ingredient A

(10) TABLE-US-00002 Ingredient Quantity [g] TMPTA .sup.1 11.9 DBU .sup.2 0.56 .sup.1 Trimethylol propane triacrylate .sup.2 1,8-diazabicyclo[5.4.0]undec-7-ene
Ingredient B

(11) TABLE-US-00003 Ingredient Quantity [g] Trimethylol propane triacetoacetate .sup.3 15.5 .sup.3 Lonzamon AATMP
Ingredient C

(12) TABLE-US-00004 Ingredient Quantity [g] as indicated above 42.0

(13) To produce a 2-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 2

(14) Ingredient A

(15) TABLE-US-00005 Ingredient Quantity [g] TMPTA 16.6 DBU 0.56
Ingredient B

(16) TABLE-US-00006 Ingredient Quantity [g] Trimethylolpropane triacetoacetate 10.8
Ingredient C

(17) TABLE-US-00007 Ingredient Quantity [g] as indicated above 42.0

(18) To produce a two-component system, ingredient C was divided between Ingredients A and B.

EXAMPLE 3

(19) Ingredient A

(20) TABLE-US-00008 Ingredient Quantity [g] Pentaerythritol triacrylate 12.0 DBU 0.56
Ingredient B

(21) TABLE-US-00009 Ingredient Quantity [g] Trimethylolpropane triacetoacetate .sup.3 15.5 .sup.3 Lonzamon AATMP
Ingredient C

(22) TABLE-US-00010 Ingredient Quantity [g] as indicated above 42.0

(23) To produce a two-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 4

(24) Ingredient A

(25) TABLE-US-00011 Ingredient Quantity [g] Pentaerythritol triacrylate 16.7 DBU 0.56
Ingredient B

(26) TABLE-US-00012 Ingredient Quantity [g] Trimethylolpropane triacetoacetate .sup.3 10.8 .sup.3 Lonzamon AATMP
Ingredient C

(27) TABLE-US-00013 Ingredient Quantity [g] as indicated above 42.0

(28) To produce a two-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 5

(29) Ingredient A

(30) TABLE-US-00014 Ingredient Quantity [g] Propoxylated glycerol triacrylate 14.4 DBU 0.7
Ingredient B

(31) TABLE-US-00015 Ingredient Quantity [g] Trimethylolpropane triacetoacetate .sup.3 13.0 .sup.3 Lonzamon AATMP
Ingredient C

(32) TABLE-US-00016 Ingredient Quantity [g] as indicated above 42.0

(33) To produce a two-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 6

(34) Ingredient A

(35) TABLE-US-00017 Ingredient Quantity [g] Propoxylated glycerol triacrylate 18.8 DBU 0.7
Ingredient B

(36) TABLE-US-00018 Ingredient Quantity [g] Trimethylolpropane triacetoacetate .sup.3 8.5 .sup.3 Lonzamon AATMP
Ingredient C

(37) TABLE-US-00019 Ingredient Quantity [g] as indicated above 42.0

(38) To produce a two-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 7

(39) Ingredient A

(40) TABLE-US-00020 Ingredient Quantity [g] TMPTA .sup.1 8.3 .sup.1 Trimethylol propane triacrylate
Ingredient B

(41) TABLE-US-00021 Ingredient Quantity [g] Trimethylol propane triacetoacetate .sup.2 10.8 K.sub.2CO.sub.3 1.0 .sup.2 Lonzamon AATMP
Ingredient C

(42) TABLE-US-00022 Ingredient Quantity [g] as indicated above 30.0

(43) To produce a two-component system, ingredient C was divided between ingredients A and B.

EXAMPLE 8

(44) Ingredient A

(45) TABLE-US-00023 Ingredient Quantity [g] TMPTA .sup.1 10.2 .sup.1 Trimethylol propane triacrylate
Ingredient B

(46) TABLE-US-00024 Ingredient Quantity [g] Trimethylol propane triacetoacetate .sup.2 8.8 K.sub.2CO.sub.3 1.0 .sup.2 Lonzamon AATMP
Ingredient C

(47) TABLE-US-00025 Ingredient Quantity [g] as indicated above 30.0

(48) To produce a two-component system, ingredient C was divided between ingredients A and B.

(49) Shrinkage with all compositions was less than 5.0%.

COMPARATIVE EXAMPLE 1

(50) A commercial fire protection product (Hilti CFP S-WB) based on aqueous dispersion technology was used for a comparison.

COMPARATIVE EXAMPLE 2

(51) A standard epoxy-amine system (Jeffamin T-403, liquid, solvent-free and crystallization-stable epoxy resin, consisting of low-molecular epoxy resins on the basis of Bisphenol A and Bisphenol F (Epilox AF 18-30, Leuna-Harze GmbH) and 1,6-hexanediol diglycidyl ether), which is filled to 60% with an intumescence mixture analogous to the above examples, was tested as an additional comparison.

COMPARATIVE EXAMPLE 3

(52) As a further comparison, a standard epoxy-amine system (isophorone diamine, trimethylol propane triacrylate and liquid, solvent-free and crystallization-stable epoxy resin, consisting of low molecular epoxy resins on the basis of Bisphenol A and Bisphenol F (Epilox AF 18-30, Leuna-Harze GmbH)), which is filled to 60% with an intumescence mixture analogous to the above examples, was tested.

(53) Table 1 shows that the relative ash crust stability, with an identical content of additive that forms an insulation layer, is significantly higher than that of comparative example 2 (Epoxy-amine system). The curing times were also significantly shorter than those of the comparative systems and are in the range of one to three hours.

(54) TABLE-US-00026 TABLE 1 Results of measurements of the intumescence factor, ash crust stability and curing time Intumescence Relative ash factor I crust stability Specimen Curing (by a AKS (by a thickness/TM time Example factor of) factor of) (millimeters) (h) 1 16 0.92 3.2 1 2 9 0.8 2.8 1 3 26 0.97 2.8 2 4 29 0.95 2.8 2 5 12 0.97 2.8 2.5 6 9 0.88 2.6 2.5 7 25 0.97 1.9 1 8 37 0.84 1.8 0.5 Comparative 36 0.62 1.8 10 days example 1 Comparative 22 0.04 1.6 12 h example 2 Comparative 1.7 0.60 1.2 1 day example 3