# US 8,784,705 B2 · Intumescent coating compositions > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,705 B2 - Document ID: US8784705B2 - Status: Granted - Kind: B2 - Application number: 10/561,936 - Filed: 2004-06-24 - Published: 2008-09-18 - Granted: 2014-07-22 - Earliest claimed: 2003-06-24 - Assignees: W. & J. Leigh & Co. - Applicants: John Daryl Green; William Allen - Inventors: John Daryl Green; William Allen - Web page: https://patentgrep.com/patent/US8784705B2 ## CPC - C09D 125/14: with unsaturated esters - C09D 5/185: {Intumescent paints} - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) ## Abstract A liquid intumescent coating composition comprising a resin system. The resin system comprises at least one polymeric component, one or more ethylenically unsaturated monomeric components and at least one intumescent ingredient. The coating composition is curable to a solid state in a free-radical polymerization reaction. ## Claims ### Claim 1 A liquid intumescent coating composition comprising at least one polymeric component, said at least one polymeric component comprises solid thermoplastic resin, at least one ethylenically unsaturated monomeric component, and at least one intumescent ingredient component comprising an acid source in combination with another intumescent ingredient, and a chemical initiator for initiating a reaction to cure the coating composition to a solid state by free radical polymerization. ### Claim 2 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein the solid thermoplastic resin comprises at least one homopolymer, copolymer and/or terpolymer of methacrylic resin. ### Claim 3 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein the solid thermoplastic resin comprises a meth(acrylate) copolymer. ### Claim 4 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein the solid thermoplastic resin comprises the reaction product of at least one of styrene or vinyl toluene together with at least one of any of the following: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, t-butyl methacrylate, 2-hydroxy ethyl methacrylate, 2-hydroxy propyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-hydroxy ethyl acrylate, 2-hydroxy propyl acrylate, and 2-ethylhexyl acrylate. ### Claim 5 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein the solid thermoplastic resin comprises the reaction product of one or more diene together with at least one any of the following: styrene, vinyl toluene, vinyl chloride, vinyl acetate, vinylidine chloride, and vinyl versatate esters. ### Claim 6 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein the ethylenically unsaturated monomeric component comprises any of the following either alone or in combination: methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, t-butyl methacrylate, 2-ethylhexyl acrylate, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, and 2-ethylhexyl acrylate. ### Claim 7 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said polymeric component and said ethylenically unsaturated monomeric component together constitutes from 20% to 60% of the coating composition. ### Claim 8 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said at least one polymeric component constitutes from 10% to 50% by weight of the combined polymeric component and ethyleincally unsaturated monomeric component. ### Claim 9 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said at least one ethylenically unsaturated monomeric component constitutes from 30% to 90% by weight of the combined polymeric component and ethylenically unsaturated monomer. ### Claim 10 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said another intumescent ingredient comprises a carbon source and a gas source. ### Claim 11 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said acid source is selected from the group consisting of: ammonium polyphosphate, melamine phosphate, magnesium sulphate, and boric acid. ### Claim 12 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said acid source constitutes from 35% to 65% by weight of the at least one intumescent ingredient component. ### Claim 13 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said acid source is coated to further reduce solubility with a coating selected from the group consisting of silane, melamine, or melamine formaldehyde. ### Claim 14 (depends on 1) A liquid intumescent coating composition as claimed in claim 1, wherein said acid source is ammonium polyphosphate coated with melamine formaldehyde. ### Claim 15 A method of curing a liquid intumescent coating composition to a solid state by free radical polymerization comprising the step of adding an organic peroxide initiator to the liquid intumescent coating composition, wherein the coating composition comprises at least one polymeric component, said at least one polymeric component comprises solid thermoplastic resin, at least one ethylenically unsaturated monomeric component and at least one intumescent ingredient component comprising an acid source in combination with another intumescent ingredient. ### Claim 16 (depends on 15) A method as claimed in claim 15, wherein the organic peroxide comprises any of the following either alone or in combination: diacyl peroxides, ketone peroxides, peroxyesters, dialkyl peroxides, hydroperoxides and peroxyketals. ### Claim 17 (depends on 15) A method as claimed in claim 15, wherein the coating composition is cured in less than 60 minutes at a temperature of 20° C.+/−3° C. ### Claim 18 (depends on 15) A method as claimed in claim 15, wherein less than 5% by weight of volatile components is lost by evaporation during the conversion of the composition to a solid state by the addition of an organic peroxide. ### Claim 19 (depends on 15) A method as claimed in claim 15, wherein said another intumescent ingredient comprises a carbon source and a gas source. ### Claim 20 (depends on 15) A method as claimed in claim 15, wherein said acid source is selected from the group consisting of: ammonium polyphosphate, melamine phosphate, magnesium sulphate, and boric acid. ### Claim 21 (depends on 15) A method as claimed in claim 15, wherein said acid source constitutes from 35% to 65% by weight of the at least one intumescent ingredient component. ### Claim 22 (depends on 15) A method as claimed in claim 15, wherein said acid source is coated to further reduce solubility with a coating selected from the group consisting of: silane, melamine, or melamine formaldehyde. ### Claim 23 A liquid intumescent coating composition comprising a solid thermoplastic resin, at least one ethylenically unsaturated monomeric component, at least one intumescent ingredient comprising an acid source in combination with another intumescent ingredient, a peroxide initiator for initiating a reaction to cure the coating composition to a solid state by free radical polymerization, and a tertiary amine catalyst. ### Claim 24 A liquid intumescent coating composition comprising at least one polymeric component, said at least one polymeric component comprises solid thermoplastic resin, at least one ethylenically unsaturated monomeric component, and at least one intumescent ingredient component comprising an acid source in combination with another intumescent ingredient, said coating composition curable to a solid state by free radical polymerization.