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US 9,097,011 B1Granted
Heat and fire resistant plastic foam
AssigneeAmerican Thermal Holdings Company
InventorsRichard J. Barone, Felix A. Dimanshteyn
Life of this patent
Estimating the term…
Abstract
A heat and fire resistant system, comprising at least one layer of an intumescent coating applied on at least one surface of a foam substrate. The intumescent coating includes an intumescent catalyst, a carbonific, a blowing agent, expandable graphite, and a binder. A method for rendering a foam substrate resistant to heat and fire, comprising applying at least one layer of intumescent coating composition onto at least one surface of the foamed substrate and allowing the intumescent coating to dry on the foamed substrate. The intumescent coating composition includes an intumescent catalyst, a carbonific, a blowing agent, expandable graphite, and a binder.
Claims43
A heat and fire resistant system, comprising:
- a foam substrate;
- and
- at least one layer of an intumescent coating directly applied to at least one surface of the foam substrate, the intumescent coating consisting essentially of an intumescent catalyst, a carbonific, a blowing agent, expandable graphite, a surfactant, and a latex binder,
- wherein the intumescent catalyst is present in an amount of about 1 to about 60 wt % of the total weight of the coating composition, the intumescent catalyst selected from the group consisting of monoammonium phosphate, diammonium phosphate, monopotassium phosphate, ammonium polyphosphate, ammonium borate, ammonium sulfate, metaphosphoric acid, orthophosphoric acid, pyrophosphoric acid, hypophosphorous acid, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, urea phosphate, and combinations thereof;
- wherein the carbonific is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition, the carbonific selected from the group consisting of polyhydric alcohol, polyhydric compounds, polyols, polysaccharides, starches, dextrins, sugar alcohols, reducing sugars, hexane hexols, pentane pentols, mannitol, sorbitol, dulictol, inositol, arabitol, pentaerythritol, dipentaerythritol, tripentaerythritol, sucrose, glucose, maltose, erythritol, dextrose, and combinations thereof;
- wherein the blowing agent is present in an amount of about 0.1 to about 50 wt % of the total weight of the coating composition, the blowing agent selected from the group consisting of melamine, melamine cyanurate, dicyandiamide, urea, dimethylurea, guanidine, cyanoguanidine, glycine, chlorinated paraffin wax, alumina trihydrate, magnesium hydroxide, zinc borate hydrate, and combinations thereof;
- wherein the latex binder, free of thermoplastic polymers, has a polymer particle diameter of about 0.001 to about 10 μm and is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition;
- wherein the expandable graphite is present in an amount of about 0.1 to about 10 wt % of the total weight of the coating composition;
- and
- wherein the foam substrate and at least one layer of intumescent coating satisfy the acceptance criteria of Section 803.2.1 of the 2006 International Building Code when tested in accordance with NFPA 286.
7 more elements
A heat and fire resistant system, comprising:
- a rigid plastic foam substrate having a density of about 0.5 to about 3.5 pcf;
- wherein the plastic foam substrate is selected from the group consisting of polyurethane, polyisocyanurate and polystyrene foam;
- and
- at least one layer of an intumescent coating having a dry film thickness of about 5 to about 25 mil directly applied to at least one surface of the foam substrate, the intumescent coating consisting essentially of:
- (a) an intumescent catalyst selected from the group consisting of diammonium phosphate, ammonium polyphosphate and monoammonium phosphate wherein the intumescent catalyst is present in an amount of about 20 to about 30 wt % of the coating composition;
- (b) a carbonific selected from the group consisting of pentaerythritol, dipentaerythritol and chlorinated paraffin wax, wherein the carbonific is present in an amount of about 5 to about 15 wt % of the coating composition;
- (c) a melamine blowing agent, wherein the blowing agent is present in an, amount of about 5 to about 20 wt % of the coating composition;
- (d) expandable graphite, wherein the expandable graphite is present in an amount of about 0.5 to about 10 wt % of the coating composition;
- (e) a latex binder, wherein the latex binder, free of thermoplastic polymers, has a polymer particle diameter of about 0.001 to about 10 μm and is present in an amount of about 10 to about 30 wt % of the coating composition;
- and
- (f) a surfactant;
- wherein the foam substrate and at least one layer of intumescent coating satisfy the acceptance criteria of Section 803.2.1 of the 2006 international Building Code when tested in accordance with NFPA 286.
9 more elements
A heat and fire resistant system, comprising:
- a foam substrate;
- and
- at least one layer of an intumescent coating directly applied to at least one surface of the foam substrate, the intumescent coating consisting essentially of:
- an intumescent catalyst, a carbonific, a blowing agent, expandable graphite, a surfactant, a mold inhibitor, and a latex binder,
- wherein the intumescent catalyst is present in an amount of about 1 to about 60 wt % of the total weight of the coating composition, the intumescent catalyst selected from the group consisting of monoammonium phosphate, diammonium phosphate, monopotassium phosphate, ammonium polyphosphate, ammonium borate, ammonium sulfate, metaphosphoric acid, orthophosphoric acid, pyrophosphoric acid, hypophosphorous acid, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, urea phosphate, and combinations thereof;
- wherein the carbonific is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition, the carbonific selected from the group consisting of polyhydric alcohol, polyhydric compounds, polyols, polysaccharides, starches, dextrins, sugar alcohols, reducing sugars, hexane hexols, pentane pentols, mannitol, sorbitol, dulictol, inositol, arabitol, pentaerythritol, dipentaerythritol, tripentaerythritol, sucrose, glucose, maltose, erythritol, dextrose, and combinations thereof;
- wherein the blowing agent is present in an amount of about 0.1 to about 50 wt % of the total weight of the coating composition, the blowing agent selected from the group consisting of melamine, melamine cyanurate, dicyandiamide, urea, dimethylurea, guanidine, cyanoguanidine, glycine, chlorinated paraffin wax, alumina trihydrate, magnesium hydroxide, zinc borate hydrate, and combinations thereof;
- wherein the latex binder, free of thermoplastic polymers, has a polymer particle diameter of about 0.001 to about 10 μm and is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition;
- wherein the expandable graphite is present in an amount of about 0.1 to about 10 wt % of the total weight of the coating composition;
- and
- wherein the foam substrate and at least one layer of intumescent coating satisfy the acceptance criteria of Section 803.2.1 of the 2006 International Building Code when tested in accordance with NFPA 286.
8 more elements
A method for rendering a foam substrate resistant to heat and fire, comprising:
- (a) applying at least one layer of intumescent coating composition directly onto at least one surface of the foam substrate;
- the intumescent coating composition consisting essentially of an intumescent catalyst, a carbonific, a blowing agent, expandable graphite, a surfactant and a latex binder,
- wherein the intumescent catalyst is present in an amount of about 1 to about 60 wt % of the total weight of the coating composition, the intumescent catalyst selected from the group consisting of monoammonium phosphate, diammonium phosphate, monopotassium phosphate, ammonium polyphosphate, ammonium borate, ammonium sulfate, metaphosphoric acid, orthophosphoric acid, pyrophosphoric acid, hypophosphorous acid, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, urea phosphate, and combinations thereof;
- wherein the carbonific is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition, the carbonific selected from the group consisting of polyhydric alcohol, polyhydric compounds, polyols, polysaccharides, starches, dextrins, sugar alcohols, reducing sugars, hexane hexols, pentane pentols, mannitol, sorbitol, dulictol, inositol, arabitol, pentaerythritol, dipentaerythritol, tripentaerythritol, sucrose, glucose, maltose, erythritol, dextrose, and combinations thereof;
- wherein the blowing agent is present in an amount of about 0.1 to about 50 wt % of the total weight of the coating composition, the blowing agent selected from the group consisting of melamine, melamine cyanurate, dicyandiamide, urea, dimethylurea, guanidine, cyanoguanidine, glycine, chlorinated paraffin wax, alumina trihydrate, magnesium hydroxide, zinc borate hydrate, and combinations thereof;
- wherein the latex binder, free of thermoplastic polymers, has a polymer particle diameter of about 0.001 to about 10 μm and is present in an amount of about 1 to about 50 wt % of the total weight of the coating composition;
- wherein the expandable graphite is present in an amount of about 0.1 to about 10 wt % of the total weight of the coating composition;
- and
- (b) allowing the intumescent coating to dry on the foam substrate,
- wherein the foam substrate and at least one layer of intumescent coating satisfy the acceptance criteria of Section 803.2.1 of the 2006 International Building Code when tested in accordance with NFPA 286.
7 more elements
Dependencies are inferred from the claim text.