Preparation and performances of novel waterborne intumescent fire retardant coatings

• A novel organic–inorganic hybrid emulsion was used as the binder of the waterborne intumescent fire retardant coating and greatly improved the fire resistance performance.
• Epoxy resin in emulsion improved the adhesion of the film to substrates (from 2 grade to 0 grade).
• Montmorillonite in emulsion greatly improved water resistance, yellowing resistance and fire resistance performance.

The core–shell organic-modified montmorillonite (OMMT)/epoxy resin/styrene-acrylic emulsion was prepared using semi-continuous seeded emulsion polymerization and used as the binder of the waterborne intumescent fire retardant coating to improve the fire resistance performance and other basic performance such as water resistance performance, anti-yellowing and adhesion to substrates. Observation with transmission electron microscopy showed that core–shell emulsion had been synthesized successfully. The small angle X-ray diffraction results showed that OMMT was exfoliated and dispersed well in the emulsion within the appropriate content. Fire resistance test, thermal analysis, scanning electron microscopy (SEM), water resistance and yellowing resistance test respectively demonstrated that OMMT greatly improve fire resistance, thermal stability, water resistance and yellowing resistance performance with the addition of in the range of 1.5–2.5 wt.%. Moreover, the core–shell styrene-acrylic emulsion with 5 wt.% epoxy resin (E-44) improve the adhesion of the film to plywood (from 2 grade to 0 grade).

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