COMPOSITION WHICH FORMS AN INSULATING LAYER AND USE OF SAID COMPOSITION

Abstract

The invention relates to a composition which forms an insulating layer and which contains a binder based on polyurea. The inventive composition, which has a relatively high expansion rate, allows application, in a simple and rapid manner, of coatings having the layer thickness required for the particular fire resistance time, it being possible to reduce the layer thickness to a minimum and nevertheless to achieve high insulating action. The inventive composition is particularly suitable for fire protection, especially as a coating for metallic and nonmetallic substrates, for instance steel components such as pillars, beams and bars, for increasing the fire resistance time.

Claims

1. An insulation layer-forming composition comprising a constituent A, which contains an isocyanate compound; a constituent B, which contains a reactive component that reacts with isocyanate compounds and is selected from compounds having at least two amino groups, wherein the amino groups are primary and/or secondary amino groups, independently of one another; a constituent C, which contains a thiol-functionalized compound; and a constituent D, which contains an insulation layer-forming additive, wherein the insulation layer-forming additive comprises a mixture, optionally containing at least one carbon source, at least one dehydrogenation catalyst and at least one blowing agent.

2. The insulation layer-forming composition according to claim 1, wherein the reactive component that reacts with the isocyanate compounds is selected from polyamines, polyether polyamines and polyaspartic acid esters or a mixture thereof.

3. The insulation layer-forming composition according to claim 2, wherein the reactive component that reacts with isocyanate compounds is a polyether polyamine, which is selected from compounds of general formula (I) ##STR00001## wherein R is the radical of an initiator for alkoxylation with 2 to 12 carbon atoms and 2 to 8 groups with active hydrogens, T is hydrogen or a C.sub.1-C.sub.4 alkyl group, V and U, independently of one another, are hydrogen or T, n is a value between 0 and 100, m is an integer between 2 and 8, where m corresponds to the number of groups with an active hydrogen that were originally contained in the initiator for alkoxylation.

4. The insulation layer-forming composition according to claim 2, wherein the reactive component that reacts with isocyanate compounds is a polyaspartic acid ester of general formula (VII): ##STR00002## wherein R.sup.1 and R.sup.2 are the same or different and stand for organic radicals that are inert with respect to isocyanate groups, R.sup.3 and R.sup.4 are the same or different and stand for hydrogen or organic radicals that are inert with respect to isocyanate groups, X stands for an n-valent organic radical that is inert with respect to isocyanate groups and n stands for an integer of at least 2.

5. The insulation layer-forming composition according to claim 4, wherein R.sup.1 and R.sup.2 in formula (VII) stand for a methyl group or ethyl group independently of one another, and R.sup.3 and R.sup.4 each stand for hydrogen.

6. The insulation layer-forming composition according to claim 4, wherein X in formula (VII) stands for a radical, obtained by removing the primary amino groups from an aliphatic polyamine.

7. The insulation layer-forming composition according to claim 6, wherein X stands for a radical obtained by removing the primary amino groups from 1,4-diaminobutane, 1,6-diaminohexane, 2,2,4- or 2,4,4-trimethyl-1,6-diaminohexane, 1-amino-3,3,5-trimethyl-5-aminomethylcyclohexane, 4,4′-diaminodicyclohexylmethane or 3,3′-dimethyl-4,4′-diaminodicyclohexylmethane, diethylene triamine and triethylene tetramine, and n stands for the number 2.

8. The insulation layer-forming composition according to claim 1, wherein constituent B also contains a polyol compound.

9. The insulation layer-forming composition according to claim 8, wherein the polyol compound is selected from polyester polyols, polyether polyols, hydroxylated polyurethanes and/or alkanes each with at least two hydroxyl groups per molecule.

10. The insulation layer-forming composition according to claim 9, wherein the polyol compound is selected from compounds comprising a basic backbone of polyester, polyether, polyurethane and/or alkanes or mixtures thereof and one or more hydroxyl groups.

11. A composition according to claim 1, wherein the one or more thiol groups of the at least one thiol-functionalized compound are bound to a monomer, an oligomer or a polymer as the backbone.

12. The insulation layer-forming composition according to claim 1, wherein the isocyanate compound is an aliphatic or aromatic basic backbone and comprises at least two isocyanate groups or a mixture of isocyanate groups.

13. The insulation layer-forming composition according to claim 1, wherein quantity ratios of constituents A and B are selected so that an equivalent ratio of isocyanate groups of the isocyanate compound to the groups that are reactive with the isocyanate group of the reactive component that reacts with isocyanate compounds is between 0.3 and 1.7.

14. The composition according to claim 1, also containing a catalyst for the reaction between the isocyanate compound and the reactive components that are reactive with the isocyanate compounds and/or with the polyol.

15. The composition according to claim 1, wherein the insulation layer-forming additive also comprises at least one thermally expandable compound.

16. The composition according to claim 1, wherein the insulation layer-forming additive also contains an ash crust stabilizer.

17. The composition according to claim 1, wherein the composition also contains organic and/or inorganic aggregates and/or additional additives.

18. (canceled)

19. A coating comprising the composition of claim 1.

20. The coating according to claim 19 for coating steel construction elements.

21. The coating according to claim 19 for coating metallic and nonmetallic substrates.

22. A fire prevention layer comprising the coating of claim 19.

23. A mutlticomponent system comprising: the insulation layer-forming composition of claim 1, wherein constituent A and constituent B are kept separately and mixed together immediately before use.

24. A two-component system comprising: the insulation layer-forming composition of claim 1, wherein component I comprises constituent A, and component II comprises constituents B and C, wherein constituent A and constituent B, and constituent A and constituent C, are arranged separately, and constituent A and constituent B and/or constituent C are mixed together immediately before use.

Description

EMBODIMENTS

[0133] For production of inventive insulation layer-forming compositions, the individual components are combined and homogenized with the help of a dissolver as described below.

[0134] The curing behavior was observed in each case and then the intumescence factor was determined and the relative ash crust stability was determined. To do so the compositions were each placed in a round PTFE mold with a diameter of 48 mm.

[0135] The curing time corresponds to the time after which the samples were nontacky and could be removed from the Teflon mold.

[0136] To determine the intumescence factor and the relative ash crust stability, a muffle furnace was preheated to 600° C. Multiple measurements of the sample thickness were performed using the graduated caliper and the average hM was calculated. Then the samples were each placed in a cylindrical steel mold and heated for 30 minutes in a muffle furnace. After cooling to room temperature, the foam height hE1 was determined initially by a nondestructive method. The intumescence factor I is calculated as follows:

i=hE1:hM  Intumescence factor I:

[0137] Next a defined weight (m=105 g) in the cylindrical steel mold was dropped from a defined height (h=100 mm) onto the foam and the foam height hE2 remaining after this partially destructive action was determined. The relative ash crust stability was then calculated as follows:

ACS=hEZ:hE1  Relative ash crust stability (ACS):

[0138] In the following examples, the following composition was used as component D.

Component D:

[0139]

TABLE-US-00001 Component Amount (g) Pentaerythritol 8.7 Melamine 8.7 Ammonium polyphosphate 16.6 Titanium dioxide 7.9

Comparative Example 1

[0140] A reactive system based on polyurethane with the following composition was used for comparison purposes:

Component 1

[0141]

TABLE-US-00002 Compounds Amount (g) Polyol.sup.1 100.0 .sup.1Desmophen ® 1150, branched polyol based on castor oil; viscosity (23° C.) 3500 ± 500 mPa .Math. s (DIN EN ISO 3219/A.3)

Component 2

[0142]

TABLE-US-00003 Compounds Amount (g) Diphenylmethane diisocyanate (MDI).sup.2 45.0 .sup.2Desmodur VL, aromatic polyisocyanate based on diphenylmethane diisocyanate; viscosity (23° C.) 90 ± 20 mPa .Math. s; NCO equivalent weight approx. 133 g/eq

Component D:

[0143]

TABLE-US-00004 Compounds Amount (g) as indicated above 163.0

Comparative Example 2

[0144] A commercial fire prevention product (Hilti CFP S-WB) based on an aqueous dispersion technology was used for the sake of comparison.

Comparative Example 3

[0145] As a further comparison, a standard epoxy-amine system (Jeffamin® T-403, liquid solvent-free and crystallization-stable epoxy resin consisting of low-molecular epoxy resins based on bisphenol A and bisphenol F (Epilox® AF 18-30, Leuna-Harze GmbH) and 1,6-hexanediol diglycidyl ether) which is 60% filled with an intumescence mixture as in the above examples.

Comparative Example 4

[0146] A standard epoxy-amine system (isophorone diamine, trimethylolpropane triacrylate and liquid solvent-free and crystallization-stable epoxy resin consisting of low-molecular epoxy resins based on bisphenol A and bisphenol F (Epilox® AF 18-30, Leuna-Harze GmbH)) which was 60% filled with an intumescence mixture similar to that in the above examples was used as an additional comparison.

Comparative Example 5

[0147] A reactive system with the following composition, which was prepared by methods similar to that described in the patent application EP 13170748 that was not published previously was used as an additional comparison:

Component 1

[0148]

TABLE-US-00005 Compounds Amount (g) Amine-functionalized resin.sup.3 18.2 Dispersing additive.sup.4 1.1 .sup.3Desmophen ® NH 1420; viscosity (25° C.) 900-2000 mPa .Math. s; amine value 199-203; equivalent weight 279 .sup.4Disperbyk-111

Component 2

[0149]

TABLE-US-00006 Compounds Amount (g) Aliphatic polyisocyanate resin based on 6.0 hexamethylene diisocyanate.sup.5 Aliphatic prepolymer based on hexamethylene 23.0 diisocyanate.sup.6 .sup.5Desmodur ® N 3900; NCO content 23.5 ± 0.5 wt % (DIN EN ISO 11 909); viscosity (23° C.) 730 ± 100 mPa .Math. s (DIN EN ISO 3219/A.3); NCO equivalent weight approx. 179 g .sup.6Desmodur XP 2599; NCO content 6 ± 0.5 wt %; viscosity (23° C.) 2500 ± 500 mPa .Math. s; NCO equivalent weight approx. 700 g

Component D:

[0150]

TABLE-US-00007 Compounds Amount (g) same as indicated above 72.2

Example 1

Components B and C

[0151]

TABLE-US-00008 Compounds Amount (g) Amine-functionalized resin.sup.7 17.6 Glycol di(3-mercaptopropionate).sup.8 7.6 .sup.7Desmophen ® NH 1420; viscosity (25° C.) 900-2000 mPa .Math. s; amine value 199-203; equivalent weight 279 g/eq .sup.8Thiocure GDMP, Bruno Bock Chemische Fabrik GmbH & Co. KG

Component A

[0152]

TABLE-US-00009 Compounds Amount (g) Aliphatic polyisocyanate resin based on 22.9 hexamethylene diisocyanate.sup.9 .sup.9Desmodur ® N 3900; NCO content 23.5 ± 0.5 wt % (DIN EN ISO 11 909); viscosity (23° C.) 730 ± 100 mPa .Math. s (DIN EN ISO 3219/A.3); equivalent weight approx. 179 g/eq

Component D

[0153]

TABLE-US-00010 Compounds Amount (g) as indicated above 72.1

Example 2

Components B and C

[0154]

TABLE-US-00011 Compounds Amount (g) Amine-functionalized resin.sup.10 8.4 Ethoxylated trimethylolpropane tri-3-mercaptopropionate.sup.11 7.3 Polyethylene glycol.sup.12 8.8 .sup.10Desmophen NH 1420; viscosity (25° C.) 900-2000 mPa .Math. s; amine value 199-203; equivalent weight 279 g/eq .sup.11Thiocure ETTMP 700; Bruno Bock Chemische Fabrik GmbH & Co. KG; viscosity approx. 200 mPa .Math. s (ISO 2555, Brookfield Spindel S62, 20 rpm); H equivalent weight 236-262 g/eq; mercaptosulfur (SH) 12.2-15.0 wt % (iodometric, PA-QW-303) .sup.12Polyglycol 600

Component A

[0155]

TABLE-US-00012 Compounds Amount (g) Aliphatic polyisocyanate resin based on 16.0 hexamethylene diisocyanate.sup.13 .sup.13Desmodur ® N 3600; viscosity (25° C.) 1100 ± 300 mPa .Math. s; NCO content 23.0 ± 0.5%; equivalent weight 183 g/eq

Component D

[0156]

TABLE-US-00013 Compounds Amount (g) as indicated above 60.0

Example 3

Components B and C

[0157]

TABLE-US-00014 Compounds Amount (g) Amine-functionalized resin.sup.14 8.4 Ethoxylated trimethylol tri-3-mercaptopropionate.sup.15 7.1 Polyethylene glycol.sup.16 8.8 .sup.14Desmophen NH 1520; viscosity (25° C.) 800-2000 mPa .Math. s; amine value 189-193; equivalent weight 290 g/eq .sup.15Thiocure ETTMP 700; Bruno Bock Chemische Fabrik GmbH & Co. KG; viscosity approx. 200 mPa .Math. s (ISO 2555, Brookfield Spindel S62, 20 rpm); H equivalent weight 236-262 g/eq; mercaptosulfur (SH) 12.2-15.0 wt % (iodometric, PA-QW-303) .sup.16Polyglycol 600

Component A

[0158]

TABLE-US-00015 Compounds Amount (g) Aliphatic polyisocyanate resin based on 15.9 hexamethylene diisocyanate.sup.17 .sup.17Desmodur N 3600; viscosity (25° C.) 1100 ± 300 mPa .Math. s; NCO content 23.0 ± 0.5%; equivalent weight 183 g/eq

Component D

[0159]

TABLE-US-00016 Compounds Amount (g) as indicated above 60.1

Example 4

Components B and C

[0160]

TABLE-US-00017 Compounds Amount (g) Amine-functionalized resin.sup.18 9.8 Glycol di(3-mercaptopropionate).sup.19 12.8 .sup.18Desmophen ® NH 1420; viscosity (25° C.) 900-2000 mPa .Math. s; amine value 199-203; equivalent weight 279 g/eq .sup.19Thiocure GDMP; Bruno Bock Chemische Fabrik GmbH & Co. KG

Component A

[0161]

TABLE-US-00018 Compounds Amount (g) Aliphatic polyisocyanate resin based on 25.5 hexamethylene diisocyanate.sup.20 .sup.20Desmodur ® N 3900; NCO content 23.5 ± 0.5 wt % (DIN EN ISO 11 909); viscosity (25° C.) 730 ± 100 mPa .Math. s (DIN EN ISO 3219/A.3); equivalent weight approx. 179 g/eq

Component D

[0162]

TABLE-US-00019 Compounds Amount (g) as indicated above 72.1

[0163] The results presented in Table 1 show clearly that curing of the compositions according to the invention takes place more rapidly than that of the comparative compositions.

TABLE-US-00020 TABLE 1 Results of the measurement of the curing time Sample thickness h.sub.A Example (mm) Curing time 1 4.5 35 min 2 3.4 30 min 3 3.3 45 min 4 5.5 4.5 min Comparative 1.8 10 days example 2 Comparative 5.1 2.25 h example 5

TABLE-US-00021 TABLE 2 Results of measurements of the intumescence factor and the ash crust stability Relative ash crust Sample Intumescence stability AKS thickness h.sub.M Example factor I (multiple) (multiple) (mm) 1 5.5 0.81 4.5 2 5.1 0.84 3.4 3 3.9 0.78 3.3 4 9.9 0.86 5.5 Comparative Sample decomposes, no intumescence 1.4 example 1 Comparative 22 0.04 1.6 example 3 Comparative 1.7 0.60 1.2 example 4 Comparative 4.8 0.76 5.1 example 5