Insulation layer-forming composition and use thereof

Abstract

Described is an insulation layer-forming composition containing a binder that is based on a compound having low-electron multiple carbon bonds and a carbanion-forming compound. The disclosed composition, which has a relatively high expansion rate, makes it possible to apply, in a simple and rapid manner, coatings that have the layer thickness required for the particular fire resistance time, the layer thickness being reduced to a minimum while achieving a great insulating effect. The disclosed composition is particularly suitable for fire protection, especially as a coating for steel components such as pillars, beams and truss members, for increasing the fire resistance time.

Claims

1. An insulation layer-forming composition comprising: a component A containing a multifunctional Michael acceptor, the Michael acceptor having at least two electron-deficient multiple carbon bonds per molecule as functional Michael acceptor groups, a component B containing a multifunctional Michael donor, the Michael donor having at least two C,H acid groups per molecule as functional Michael donor groups, a component C containing a compound having an X—H group, the compound being capable of reacting with component A and X standing for N, P, O, S, or C, with the provision that, when X stands for C, C is part of an acid methyl group, a component D containing a catalyst for a Michael addition reaction, and a component E containing an insulation layer-forming additive.

2. The composition as recited in claim 1 wherein the functional Michael acceptor groups have structure (I) or (II): ##STR00003## where R.sup.1, R.sup.2, and R.sup.3 represent, independently of each other, hydrogen, a linear, branched, or cyclic, possibly substituted alkyl group, aryl group, aralkyl group, or alkylaryl group; which may contain, independently of each other, additional ether groups, carboxyl groups, carbonyl groups, thiol analog groups, nitrogen-containing groups, or combinations thereof; X represents O, S, or NR.sup.4, where R.sup.4 represents hydrogen or any of the organic groups as described for R′, R.sup.2, and R.sup.3; Y represents OR.sup.5, SR.sup.5, or NR.sup.5R.sup.6, where R.sup.5 and R.sup.6 represent hydrogen or any of the organic groups as described above for R.sup.1, R.sup.2, and R.sup.3.

3. The composition as recited in claim 2 wherein each functional Michael acceptor group is connected to another functional Michael acceptor group, which may be identical or different, or a skeleton via one or more of R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5, or R.sup.6.

4. The composition as recited in claim 3 wherein the functional Michael acceptor groups are connected to a polyol compound, an oligomer or polymer via R.sup.4, R.sup.5, or R.sup.6.

5. The composition as recited in claim 1 wherein the functional Michael donor groups are selected from the group consisting of β-ketoesters, β-ketoamides, 1,3-diketons, malonic esters and malonic ester derivatives, cyanoacetate esters, cyanoacetamides, and α-nitroalkanes.

6. The composition as recited in claim 1 wherein the functional Michael acceptor groups or the functional Michael donor groups are connected, independently of each other, to a polyol group selected from the group consisting of: pentaerythriol, neopentyl glycol, glycerol, trimethylol propane, ethylene glycol, and polyethylene glycols, propylene glycols, and polypropylene glycols, butanediol, pentanediol, hexanediol, tricyclodecane dimethylol, 2,2,4-trimethyl-1,3-pentanediol, bisphenol A, cyclohexane dimethanol, alkoxylated and/or propoxylated derivatives of neopentyl glycol and tetraethylene glycol.

7. The composition as recited in claim 1 wherein the X—H group of component C is characterized by a pKa (determined in aqueous medium) less by an integer unit than a further pKa of dominant C—H groups in component B.

8. The composition as recited in claim 1 wherein the X—H groups in component C are contained in a proportion of at least 50 mol % relative to quantity of base which is released by component D.

9. The composition as recited in claim 1 wherein the X—H groups in component C are contained in a proportion no greater than 30 mol % relative to the C—H acid groups of component B.

10. The composition as recited in claim 1 wherein, in addition to component C, another component B2 is present and contains a further compound having acid protons (C—H) in an activated methylene group or methine group, the further compound having a higher acidity compared with component B and is capable of reacting with component A.

11. The composition as recited in claim 10 wherein the C—H groups in component B2 are contained in a proportion between 1 and 50 mol % relative to the total C—H groups in component B.

12. The composition as recited in claim 1 wherein the reactive equivalent ratio is in the range of 0.1:1 to 10:1.

13. The composition as recited in claim 1 wherein the insulation layer-forming additive is a mixture and/or includes at least one thermally expandable compound.

14. The composition as recited in claim 13 wherein the mixture includes at least one carbon source, at least one dehydration catalyst, and at least one propellant.

15. The composition as recited in claim 13 wherein the insulation layer-forming additive also contains an ash crust stabilizer.

16. The composition as recited in claim 1 wherein the composition contains additional organic and/or inorganic substances and/or other additives.

17. The composition as recited in claim 1 wherein the composition is a two-component or multicomponent system.

18. The composition as recited in claim 1 wherein the insulation layer-forming additive is contained in one component or multiple components as a mixture or divided into individual components.

19. The composition as recited in claim 18 wherein the insulation layer-forming additive also contains an ash crust stabilizer and wherein the ash crust stabilizer is contained in one component or distributed to the components.

20. A method for using of the composition as recited in claim 1 comprising applying the composition as a coating.

21. A method for using of the composition as recited in claim 1 comprising coating steel construction elements or non-metallic building components with the composition.

22. A method for using of the composition as recited in claim 1 comprising coating individual cables, cable bundles, cable routes, cable channels, or other lines with the composition.

23. A method for using of the composition as recited in claim 1 comprising applying the composition as fire protection coating.

Description

EXEMPLARY EMBODIMENTS

(1) The components that are listed below are used for producing the insulation layer-forming compositions according to the present invention. The individual components are diluted using a solvent and homogenized. These mixtures are then mixed for use prior to or, preferably during, spraying and applied.

(2) The curing behavior of the composition is monitored, and the intumescence factor and the relative ash crust stability are then determined. For this purpose, the mass is provided in a round, 2 mm deep teflon form having a 48 mm diameter.

(3) The curing time corresponds to the time after which the samples are fully hardened and can be removed from the teflon form.

(4) For determining the intumescence factor and the relative ash crust stability, a muffle oven is preheated to 600° C. The thickness of the sample is measured multiple times using a caliper and the mean value h.sub.M is calculated. The samples are then inserted into a cylindrical steel form and heated in the muffle oven for 30 min. After cooling to room temperature, the foam height h.sub.E1 is initially determined destruction-free (mean value of the multiple measurements). The intumescence factor is determined by the formula:
Intumescence factor I:I=h.sub.E1:h.sub.M

(5) A defined weight is then dropped in the cylindrical steel form (m=105 g) onto the foam from a defined height (h=100 mm) and the foam height h.sub.E2 remaining after this partially destructive action is determined. The relative ash crust stability is determined by the formula:
Relative ash crust stability (AKS): AKS=h.sub.E2:h.sub.E1

(6) For the following examples 1 through 8 and comparative examples 2 and 3, the following composition is used as component E and the composition is used in the given quantities:

(7) Component E:

(8) TABLE-US-00002 Qty Component [g] Pentaerythrite 8.7 Melamine 8.7 Ammonium polyphosphate 16.6 Titanium dioxide 7.9

Example 1

Component A with D

(9) TABLE-US-00003 Qty Component [g] TMPTA.sup.1 11.9 DBU.sup.2 0.56 .sup.1Trimethylol propane triacrilate .sup.21,8-diazabicyclo[5.4.0]undec-7-ene

Component B

(10) TABLE-US-00004 Qty Component [g] Trimethylolpropane triacetoacetate.sup.3 15.5 .sup.3Lonzamon AATMP

Component E

(11) TABLE-US-00005 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 2

Component A with D

(12) TABLE-US-00006 Qty Component [g] TMPTA 16.6 DBU 0.56

Component B

(13) TABLE-US-00007 Qty Component [g] Trimethylolpropane triacetoacetate 10.8

Component E

(14) TABLE-US-00008 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 3

Component A with D

(15) TABLE-US-00009 Qty Component [g] Pentaerythritol triacrylate 12.0 DBU 0.56

Component B

(16) TABLE-US-00010 Qty Component [g] Trimethylolpropane triacetoacetate.sup.3 15.5 .sup.3Lonzamon AATMP

Component E

(17) TABLE-US-00011 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 4

Component A with D

(18) TABLE-US-00012 Qty Component [g] Pentaerythritol triacrylate 16.7 DBU 0.56

Component B

(19) TABLE-US-00013 Qty Component [g] Trimethylolpropane triacetoacetate.sup.3 10.8 .sup.3Lonzamon AATMP

Component E

(20) TABLE-US-00014 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 5

Component A with D

(21) TABLE-US-00015 Qty Component [g] Propoxylated glycerol triacrylate 14.4 DBU 0.7

Component B

(22) TABLE-US-00016 Qty Component [g] Trimethylolpropane triacetoacetate.sup.3 13.0 .sup.3Lonzamon AATMP

Component E

(23) TABLE-US-00017 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 6

Component A with D

(24) TABLE-US-00018 Qty Component [g] Propoxylated glycerol triacrylate 18.8 DBU 0.7

Component B

(25) TABLE-US-00019 Qty Component [g] Trimethylolpropane triacetoacetate.sup.3 8.5 .sup.3Lonzamon AATMP

Component E

(26) TABLE-US-00020 Qty Component [g] As above 42.0
To produce a two-component system, component E is divided into components A, containing component D, and B.

Example 7

Component A

(27) TABLE-US-00021 Qty Component [g] TMPTA.sup.1 8.3 .sup.1trimethylolpropane triacrylate

Component B with D

(28) TABLE-US-00022 Qty Component [g] Trimethylolpropane triacetoacetate.sup.2 10.8 K.sub.2CO.sub.3 1.0 .sup.2Lonzamon AATMP

Component E

(29) TABLE-US-00023 Qty Component [g] As above 30.0
To produce a two-component system, component E is divided into components A and B, containing component D.

Example 8

Component A

(30) TABLE-US-00024 Qty Component [g] TMPTA.sup.1 10.2 .sup.1trimethylolpropane triacrylate

Component B with D

(31) TABLE-US-00025 Qty Component [g] Trimethylolpropane triacetoacetate.sup.2 8.8 K.sub.2CO.sub.3 1.0 .sup.2Lonzamon AATMP

Component E

(32) TABLE-US-00026 Qty Component [g] As above 30.0
To produce a two-component system, component E is divided into components A and B, containing component D.
The shrinkage for all compositions was less than 5.0%.

Comparative Example 1

(33) A commercially available fire protection product (Hilti CFP S-WB) based on aqueous dispersion technology was used for comparison.

Comparative Example 2

(34) A standard epoxy-amine system (Jeffamine® T-403, a liquid, solvent-free and crystallization-stable epoxy resin, composed of low-molecular, bisphenol A and bisphenol F-based epoxy resins (Epilox® AF 18-30, Leuna-Harze GmbH) and 1,6-hexanediol diglycidyl ether)), 60% supplemented with an intumescence mixture as in the above examples, was used for further comparison and tested.

Comparative Example 3

(35) A standard epoxy-amine system (isophorondiamine trimethylolpropane triacrylate and a liquid, solvent-free and crystallization-stable epoxy resin, composed of low-molecular, bisphenol A and bisphenol F-based epoxy resins (Epilox® AF 18-30, Leuna-Harze GmbH)), 60% supplemented with an intumescence mixture as in the above examples, was used for further comparison and tested.

(36) Table 1 shows that the relative ash crust stability for the same proportion of insulation layer-forming additive is substantially higher than that of Comparative Example 2 (epoxy-amine system). The curing times were also substantially reduced compared to the comparative systems and amounted to one to three hours.

(37) TABLE-US-00027 TABLE 1 Results of the measurements of the intumescence factor, the ash crust stability, and the curing time Relative Ash Sample Intumescence Crust Stability Thickness Curing Factor I AKS h.sub.M time Example (multiple) (multiple) (mm) (hr) 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 hrs Example 2 Comparative 1.7 0.60 1.2 1 day Example 3