Stock material or miscellaneous articles – Composite – Of epoxy ether
Reexamination Certificate
2000-07-07
2002-10-29
Dawson, Robert (Department: 1712)
Stock material or miscellaneous articles
Composite
Of epoxy ether
C106S018110, C106S018180, C252S606000, C252S609000, C523S179000, C523S468000
Reexamination Certificate
active
06472070
ABSTRACT:
FIELD OF THE INVENTION
This invention relates in general to a fire-resistant paint, and more particularly to a fire-resistant paint which is used to improve the fire-resistance of building materials by means of coating.
BACKGROUND OF THE INVENTION
In the field of building materials fire-resistance has an important meaning. Recently, as the applications of resin materials expand, resin materials are widely used for building materials and resin materials with fire-resistant properties are desired.
For such fire-resistance properties, not only the resin material itself is required to resist combustion, but the resin material is also required to protect the building material from flames when it is used as a fire-resistant coating material on building materials. Although the intrinsic nature of resin materials is to burn and melt, they must not burn or melt and come off when they are used as fire-resistant materials.
A fire-resistant coating is sometimes applied in advance on beams, columns, and such because of the desire to reduce the processes on the construction site. However, coating cannot be applied in advance on beam-column joints, junctions, and metal fixtures for installing outer walls and such. These parts have to be done on the construction site. For application on the construction site, painting such as by spraying is easier to implement than coating with a coating material in a sheet or board form. Painting is also more preferable when coating a structure with a complex form.
For a spray type fire-resistant coating, rockwool spraying is common, but this requires a thicker coating to satisfy the fire-resistant properties. Fire-resistant paint is widely known to give a thinner fire-resistant coating. However, conventional fire-resistant paint has problems in that the residue after heat expansion is fragile and so the residue after expansion may come off, and also that it contains polyhydric alcohol which has a high solubility in water, resulting in water resistance problems and requiring a top coat layer on the paint surface.
In view of what is described above, a fire-resistant paint with both a thin coating thickness and a solid residue after expansion is desired. The object of the present invention is to provide a heat expanding fire-resistant paint which manifests particularly prominent fire-resistant performance by leaving a residue with sufficient shape retaining properties after combustion, is safe for human body, and is easily coated on any part.
The problems which have been solved by the present invention are described below by referring to specific conventional technology.
{circle around (1)} Japanese unexamined patent publication Tokkai Sho 58-2356 and Tokkai Sho 57-67673 discloses fire protective butyl rubber paint. When lamination with other components is done after butyl rubber paint is applied and air dried, fasteners such as screws and/or nails have to be used for securing, which causes cracks and/or fissures resulting in reduced fire-resistance performance. In order to improve on this issue, Tokkai Sho 58-2356 and Tokkai Sho 57-67673 disclose a paint which uses butyl rubber for the resin binder. However, antimony trioxide, in the case of Tokkai Sho 57-67673, and asbestos and/or halogen, in the case of Tokkai Sho 58-2356, have to be added for sufficient fire-resistance performance. There is a problem in that these substances can have adverse effects on the human body during manufacturing, applying, burning, etc. On the other hand, the fire-resistant paint of the present invention can achieve superior fire-resistant performance using substances which are safe to the human body.
{circle around (2)} Japanese examined patent publication Tokko Sho 63-7238 illustrates a foaming fire-protective composition composed of thermally expandable graphite and a phosphorus compound. A low molecular weight hydrocarbon (or derivative) is used to give a putty form to this composition. When this is used on a vertical site and heated, sagging occurs before foaming due to its insufficient retaining property resulting in insufficient fire-protective performance. On the other hand, the fire-resistant paint of the present invention can be assured to have a sufficient retaining property by proper selection of the resin binder so there is no sagging before foaming when used on a vertical site and heated. Therefore, it can manifest sufficient fire-resistant performance regardless of heating conditions.
{circle around (3)} Tokkai Hei 5-70540 illustrates a paint which uses thermally expandable graphite, a phosphorus compound, a polyhydric alcohol, and a nitrogen-containing compound-based foaming agent, with urethane resin for the binder. However, since a polyhydric alcohol which is highly soluble in water is used, there is a problem in terms of water resistance of the paint, requiring top coating. When a polyhydric alcohol is not used, the residue does not have sufficient strength.
{circle around (4)} Tokkai Hei 9-227716 and Tokkai Hei 10-7838 propose a fire-resistant resin composition which leaves a firm residue after expansion. However, because of its viscosity, it is hard to use as a coating paint.
{circle around (5)} Publication WO98/31730 of PCT application (PCT/JP97/02258) illustrates a thermally expandable fire-resistant molded sheet. However, since this is a molded sheet, covering special sites on a building component is difficult.
{circle around (6)} Tokkai Hei 9-183978 illustrates a foaming composition for a fire-resistant paint which is an acrylic resin containing low temperature expandable graphite, a phosphoric acid compound, melamine, and a polyhydric alcohol. However, since a polyhydric alcohol which is highly soluble in water is used, there is a problem in terms of water resistance of the paint, requiring top coating. When a polyhydric alcohol is not used, the residue does not have sufficient strength.
Compared with these, the fire-resistant paint of the present invention can be applied on any site, can ensure sufficient residue strength without using a polyhydric alcohol, and has no problems in terms of water resistance.
DISCLOSURE OF THE INVENTION
(1) The first (claim) of the present invention is a fire-resistant paint containing an epoxy resin, a hardener, and an inorganic filler wherein
{circle around (1)} for the total of 100 weight parts of the epoxy resin and the hardener,
{circle around (2)} 200-500 weight parts of the inorganic filler, chosen from a group consisting of neutralized thermally expandable graphite, metal carbonate, and a hydrated inorganic compound is contained;
{circle around (3)} for the inorganic filler, at least 15-400 weight parts of neutralized thermally expandable graphite is contained; and
{circle around (4)} the viscosity of the fire-resistant paint is 1-1,000 ps as measured by a B-type viscometer.
(2) The second (claim) of the present invention is a fire-resistant paint containing an epoxy resin, a hardener, and an inorganic filler wherein
{circle around (1)} for the total of 100 weight parts of the epoxy resin and the hardener,
{circle around (2)} 15-400 weight parts of neutralized thermally expandable graphite and a phosphorus compound is contained;
{circle around (3)} the weight ratio between the neutralized thermally expandable graphite and the phosphorus compound is (thermally expandable graphite/phosphorus compound)=0.01-9;
{circle around (4)} 10-400 weight parts of a metal carbonate and/or hydrated inorganic compound is contained;
{circle around (5)} the total amount of the neutralized thermally expandable graphite and phosphorus compound, and the metal carbonate and/or hydrated inorganic compound is 200-500 weight parts; and
{circle around (6)} the viscosity of the fire-resistant paint is 1-1,000 ps as measured by a B-type viscometer.
(3) The third (claim) of the invention is a fire-resistant paint containing butyl rubber or isobutylene rubber and an inorganic filler wherein
{circle around (1)} Flory's viscosity-average molecular weight of the butyl rubber or isobutylene rubber is 5,000-4,000,000; and
{circle around (
Muraoka Hitomi
Okada Kazuhiro
Tono Masaki
Aylward D.
Dawson Robert
Sekisui Chemical Co. Ltd.
Townsend & Banta
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