Flame retardant coating

Abstract

A flame retardant coating is disclosed. The flame retardant coating comprises polyurea elastomer, spray processable graphite, a graphite stabilizer agent, and a flame retardant. A method of manufacturing a flame retardant polyurea elastomer coating is also disclosed. A two part polymerizable system is provided comprising a first part containing isocyanates, and a second part containing polyamines. At least one of the first part and the second part contains a flame retardant, and both of spray processable graphite and a graphite stabilizer agent. The first part and the second part are then mixed to form the flame retardant polyurea elastomer coating.

1 . A flame retardant coating comprising:
 polyurea elastomer;   spray processable graphite;   a graphite stabilizer agent; and   a flame retardant.   
     
     
         2 . The flame retardant coating of  claim 1  further comprising thixatrol as a graphite suspending agent. 
     
     
         3 . The flame retardant coating of  claim 1  in which the graphite stabilizer agent comprises at least one of ammonium polyphosphate, zinc polyborate, melamine polyphosphate, melamine pyrophosphate, triethyl phosphate, and zinc phosphate. 
     
     
         4 . The flame retardant coating of  claim 1  further comprising a mineral matrix agent. 
     
     
         5 . The flame retardant coating of  claim 4  in which the mineral matrix agent comprises at least one of glass and perlite. 
     
     
         6 . The flame retardant coating of  claim 1  formed by a two-part polymerizable system. 
     
     
         7 . The flame retardant coating of  claim 1  in which the spray processable graphite is 50-110 mesh, with at least 50% of the spray processable graphite being between 50 and 70 mesh. 
     
     
         8 . The flame retardant coating of  claim 1  used as flooring in a transport vehicle. 
     
     
         9 . The flame retardant coating of  claim 1  used as fire protection for structural steel. 
     
     
         10 . The flame retardant coating of  claim 1  used as a rock reinforcing coating in an underground mine. 
     
     
         11 . A method of manufacturing a flame retardant polyurea elastomer coating, the method comprising:
 providing a two part polymerizable system comprising a first part containing isocyanates, and a second part containing polyamines, in which at least one of the first part and the second part contains a flame retardant, and both of spray processable graphite and a graphite stabilizer agent;   mixing the first part and the second part to form the flame retardant polyurea elastomer coating.   
     
     
         12 . A method of adhering a flame retardant polyurea elastomer coating to a smooth surface, the method comprising:
 providing a first part containing isocyanates, and a second part containing polyamines, in which at least one of the first part and the second part contains a flame retardant, a mineral matrix agent, and both of spray processable graphite and a graphite stabilizer agent;   mixing the first part and the second part to form the flame retardant polyurea elastomer coating on the smooth surface.   
     
     
         13 . The method of  claim 12  in which the smooth surface comprises metal. 
     
     
         14 . The method of  claim 12  in which the smooth surface comprises phenolic composite panels. 
     
     
         15 . A method of manufacturing a flame retardant polyurea elastomer coating, the method comprising:
 providing a two part polymerizable system comprising a first part containing isocyanates, and a second part containing polyamines, in which at least one of the first part and the second part contains both of spray processable graphite and thixatrol as a graphite suspending agent;   mixing the first part and the second part to form the flame retardant polyurea elastomer coating.   
     
     
         16 . A flame retardant composition comprising:
 polymer matrix comprising at least one of polyurethane and polyurea;   spray processable graphite;   a graphite stabilizer agent; and   a flame retardant.   
     
     
         17 . The flame retardant composition of  claim 16  further comprising thixatrol as a graphite suspending agent. 
     
     
         18 . The flame retardant composition of  claim 16  in which the polymer matrix comprises polyurethane.