INUMESCENT TECHNOLOGY FOR THERMOSET RESINSINUMESCENT TECHNOLOGY FOR THERMOSET RESINS

PHILIP S. RHODESBROADVIEW TECHNOLOGIES

NOV. 14-15, 2005

PHILIP S. RHODESBROADVIEW TECHNOLOGIES

NOV. 14-15, 2005

INTUMESCENT TECHNOLGYINTUMESCENT TECHNOLGY

Provides fire protection by building a continuous char foam layer on the polymer surface when exposed to heat or flame.

Provides fire protection by building a continuous char foam layer on the polymer surface when exposed to heat or flame.

Different types of fire retardants

Different types of fire retardants

Halogenated additives and resins

Water releasing additivesIntumescing agents/ char formers

Activated intumescing agents

Halogenated additives and resins

Water releasing additivesIntumescing agents/ char formers

Activated intumescing agents

Halogenated additives and resins

Halogenated additives and resins

PROS

Cost effectiveEfficient at low loading levels

PROS

Cost effectiveEfficient at low loading levels

CONS

Harmful thermal decomposition products

Dioxins produced when burned in resource recovery plants

CONS

Harmful thermal decomposition products

Dioxins produced when burned in resource recovery plants

Water releasing additives

Water releasing additives

PROS

Low cost

PROS

Low cost

CONS

High loading levelsOnly provides short term protection

CONS

High loading levelsOnly provides short term protection

Intumescent agentsIntumescent agents

PROS

Non hazardous thermal decomposition products

Long term fire and thermal protection

PROS

Non hazardous thermal decomposition products

Long term fire and thermal protection

CONS

High loading levels

Only work with select resins

May require synergists

CONS

High loading levels

Only work with select resins

May require synergists

Activated intumescent agents

Activated intumescent agents

PROS

Long term thermal protection

Low-moderate loading levels

Work with a wide variety of resins

PROS

Long term thermal protection

Low-moderate loading levels

Work with a wide variety of resins

CONS

Moderately expensive

Still require the right resin-intumescent agent match

CONS

Moderately expensive

Still require the right resin-intumescent agent match

Intumescent agentsIntumescent agents

How do they work?How do they work?

Intumescent agents are catalysts for char formation

They convert to mineral acids when heated but are non acidic at temperatures below 200 C

Catalyze dehydration reactionsWork best with organic compounds that can undergo dehydration reactions

Intumescent agents are catalysts for char formation

They convert to mineral acids when heated but are non acidic at temperatures below 200 C

Catalyze dehydration reactionsWork best with organic compounds that can undergo dehydration reactions

Classic dehydration reaction

Classic dehydration reaction

R-OH + R’OH + ACID = R-O-R’ + HOH

= R-O-R + HOH

=R’-O-R’ + HOH

R-OH + R’OH + ACID = R-O-R’ + HOH

= R-O-R + HOH

=R’-O-R’ + HOH

What types of compounds readily

undergo dehydration reactions

What types of compounds readily

undergo dehydration reactionsStarches

SugarsCellulosicsPentaerythritol

StarchesSugarsCellulosicsPentaerythritol

Starch

(C6 H10 O5)n

Starch

(C6 H10 O5)n

Pentaerythritol

C5 H10 O4

Pentaerythritol

C5 H10 O4

Can intumescent agents work if the carbons do

not contain a oxygen/nitrogen

functional group?

Can intumescent agents work if the carbons do

not contain a oxygen/nitrogen

functional group?

The answer is YES.The answer is YES.

Two approaches to overcome a low number of functional groups

Two approaches to overcome a low number of functional groups

The addition of additives that contain a high number of functional groups such as pentaerythritol and melamine

Use of an activated intumescent agent

The addition of additives that contain a high number of functional groups such as pentaerythritol and melamine

Use of an activated intumescent agent

What is an activated intumescent agent?

What is an activated intumescent agent?

An intumescent agent that will help add functional

groups onto hydrocarbons when they do not exist.

An intumescent agent that will help add functional

groups onto hydrocarbons when they do not exist.

When polymers start thermal decomposition

what happens?

When polymers start thermal decomposition

what happens?Hydrogens are stripped off forming carbon-carbon double bonds

The hydrogen combines with oxygen in the vapor phase to produce water vapor and heat

The carbon bonds break and low molecular weight alkenes enter the vapor phase

These alkenes are further split and oxidized to produce CO, COO and HOH

Hydrogens are stripped off forming carbon-carbon double bonds

The hydrogen combines with oxygen in the vapor phase to produce water vapor and heat

The carbon bonds break and low molecular weight alkenes enter the vapor phase

These alkenes are further split and oxidized to produce CO, COO and HOH

What happens in the presence of an

activated intumescent

What happens in the presence of an

activated intumescentHydrogens are stripped off forming carbon-carbon double bonds

The hydrogen combines with oxygen in the vapor phase to produce water vapor and heat

The water vapor adds back across the double bonds via a catalytic route

The hydroxyls formed combine to form thermally stable ether linkages that produce char

During this dehydration reaction water is released cooling the polymer via a ablative mechanism

Hydrogens are stripped off forming carbon-carbon double bonds

The hydrogen combines with oxygen in the vapor phase to produce water vapor and heat

The water vapor adds back across the double bonds via a catalytic route

The hydroxyls formed combine to form thermally stable ether linkages that produce char

During this dehydration reaction water is released cooling the polymer via a ablative mechanism

Epoxy exampleEpoxy example

Formulation

DER 331 10ANC. 350A 4.5

INTU. AC2BG 1.5

Formulation

DER 331 10ANC. 350A 4.5

INTU. AC2BG 1.5

PROPERTIES(5 mil coating)Char yield 66%Char ht(mil) 1000Expansion 200 xProtection 40 m

PROPERTIES(5 mil coating)Char yield 66%Char ht(mil) 1000Expansion 200 xProtection 40 m

Urethane exampleUrethane example

Formulation

Poly diol61

TMP 2.5Int AC2hph36.5

MDI 22.5

Formulation

Poly diol61

TMP 2.5Int AC2hph36.5

MDI 22.5

Properties(5 mil coating)Char yield 62%Char ht 250Expansion 50xProtection 29 m

Properties(5 mil coating)Char yield 62%Char ht 250Expansion 50xProtection 29 m

Styrene acrylicStyrene acrylic

Formulation

RH TR (50%s) 10Intu AC3WM 3

Formulation

RH TR (50%s) 10Intu AC3WM 3

Properties(5 mil dry coating)Char yield 76%Char ht 450Expansion 90xProtection 36 m

Properties(5 mil dry coating)Char yield 76%Char ht 450Expansion 90xProtection 36 m

PolypropylenePolypropylene

Formulation

Polpropylene 10Plasticizer

1Intu AC-3

3

Formulation

Polpropylene 10Plasticizer

1Intu AC-3

3

Properties (5 mil film on steel) Char yield 70% Char ht 60 Expansion 12x Protection 18 m

Properties (5 mil film on steel) Char yield 70% Char ht 60 Expansion 12x Protection 18 m