Patent ID: 9097011
Filing Date: 2015-08-04
Classification: B05D,C08J,C09D,E04B

Abstract:
1. 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.