Flame-retardant powder coating

Abstract

The present disclosure relates to a flame retardant powder coating composition comprising: a) a film forming component; b) a source of phosphoric acid; and c) a filler material comprising clay, calcium carbonate, aluminum hydroxide or clay and silica. The present disclosure also discloses a substrate coated with the powder coating composition and a method of coating a substrate.

Description

Technical Field

[0001] The present disclosure relates to flame retardant powder coating compositions, methods for coating substrates with the compositions, substrates coated with the compositions, and articles comprising the substrates, including energy storage devices. Background Art

[0002] Flame retardant coatings have been used in various structural applications to prevent both cellulose fires and hydrocarbon fires. Such coatings provide protection by providing fire resistance to the coated substrate. Many substrates may benefit from being coated with such coatings, including structural building components for commercial and transportation infrastructure (such as hotels, airports, concert halls, offshore sites, chemical plants, oil drilling platforms, etc.), which are exposed to extreme heat in the event of a fire. Energy storage devices, such as batteries, including lithium-ion batteries, may also be exposed to such intense heat. Many such devices are susceptible to thermal runaway, during which heat and gas are rapidly released and create a fire hazard. Therefore, there is a need for improved flame retardant coatings, including those for energy storage devices. Summary of the Invention

[0003] The present disclosure relates to a flame retardant powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler material comprising clay and, optionally, silica, wherein the clay and, optionally, silica combined are present in an amount greater than 5 weight percent, based on the total weight of the composition.

[0004] The present disclosure relates to a flame retardant powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler material comprising calcium carbonate, wherein the calcium carbonate is present in an amount greater than 10 wt. %, based on the total weight of the composition, when the composition comprises titanium dioxide in an amount of at least 5 wt. %.

[0005] The present disclosure relates to a flame retardant powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler material comprising aluminum hydroxide, wherein the aluminum hydroxide is present in an amount greater than 10 wt. %, based on the total weight of the composition, when the composition comprises titanium dioxide in an amount of at least 5 wt. %; and wherein the composition further comprises less than 5 wt. % of an organosilane.

[0006] Also disclosed herein is a substrate coated with a powder coating composition comprising: a) a film-forming component; b) a source of phosphoric acid; and c) a filler material comprising clay and, optionally, silica, wherein the clay and, optionally, silica combined are present in an amount greater than 5 weight percent, based on the total weight of the composition.

[0007] Also disclosed herein is a substrate coated with a powder coating composition comprising: a) a film-forming component; b) a source of phosphoric acid; and c) a filler material comprising calcium carbonate, wherein the calcium carbonate is present in an amount greater than 10 wt. %, based on the total weight of the composition, when the composition comprises titanium dioxide in an amount of at least 5 wt. %, based on the total weight of the composition.

[0008] Also disclosed herein is a substrate coated with a powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler material comprising aluminum hydroxide, wherein the aluminum hydroxide is present in an amount greater than 10 weight percent, based on the total weight of the composition, when the composition comprises titanium dioxide in an amount of at least 5 weight percent, and wherein the composition further comprises less than 5 weight percent of an organosilane.

[0009] Further disclosed herein is a method of coating a substrate, the method comprising: optionally electrodepositing a coating from an electrodepositable coating composition onto at least a portion of a surface of the substrate to form an electrodeposited coating layer; and applying a flame retardant powder coating composition to at least a portion of the surface of the substrate or to the electrodeposited coating layer (if present) by electrostatic spraying or fluidized bed application to form a flame retardant powder coating layer. DETAILED DESCRIPTION

[0010] The present disclosure relates to a powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler.

[0011] A coating composition refers to a solution, mixture, powder or dispersion that is capable of producing a film or the like on at least a portion of a substrate surface in an at least partially dried or cured state. As used herein, a powder coating composition refers to any coating composition in the form of a particulate, co-reactive solid that is substantially or completely free of water and / or solvent.

[0012] The present coating composition can be used to form a flame retardant coating. As used herein, "flame retardant" means a coating layer that minimizes the possibility of fire. According to the present disclosure, a "flame retardant" coating layer is a substance that, when applied to one side of a 0.8mm to 1.2mm thick steel plate and cured to a dry film thickness of 600 microns + / - 100 microns, and the uncoated side of the substrate is exposed to a torch fire of 1450°C ± 50°C at a heat output of> 5kW, will not catch fire after being exposed to the flame for five minutes, and when the coke directly above the flame impact area is cut to expose the substrate (and still subjected to flames), it will not catch fire after being exposed to such heat output for five minutes. This test is intended to simulate a thermal runaway event in a battery and is referred to herein as a "thermal runaway test".

[0013] The flame retardant powder coating composition includes a film-forming component. As used herein, the term "film-forming component," which can be used interchangeably with "binder," refers to an ingredient, a film-forming material, that holds all the coating composition components together in the coating layer during curing. The binder includes one or more film-forming resins that can be used to form the coating layer. The binder may optionally further include one or more crosslinking agents. The one or more crosslinking agents can be selected from any of the crosslinking agents known in the art for reacting with one or more side chains and / or terminal functional groups of the one or more film-forming resins used in the powder coating composition. "Film-forming" means that the composition can form a continuous film on a surface after drying and / or curing. Any film-forming resin can be used in accordance with the present disclosure. As used herein, the term "film-forming resin" can be used interchangeably with "polymer" or "resin" and refers to one or more polymers, such as homopolymers and / or copolymers, as well as prepolymers, oligomers, and monomers, that are capable of forming a film when reacting with a curing agent or crosslinking agent, or by drying or self-crosslinking. As used herein, the terms "crosslinker," "curing agent," and similar terms refer to molecules that can form covalent bonds between polymers or between two different regions of the same polymer.

[0014] The film-forming components of the powder coating composition can be thermosetting or thermoplastic. Thermosetting or thermosetting coating compositions can cure or crosslink under ambient conditions or when exposed to heat or other energy sources. Curing refers to bond formation (such as bond formation between a polymer and a crosslinking agent) or self-crosslinking, resulting in the formation of a crosslinked coating layer film. Ambient conditions refer to temperatures typically found in the room or area where the coating composition is applied to the substrate, for example, 10°C to 40°C, while hot or baking conditions ("heat") refer to temperatures above ambient temperature. Thermoplastic coating compositions may coalesce to form a film when exposed to an energy source (such as heat).

[0015] The limiting examples of suitable film-forming resins of at least a portion of the adhesive that can form powder coating compositions include (meth) acrylate resins, polyurethanes, polyesters, polyamides, polyethers, polysiloxanes, epoxy resins, vinyl resins, copolymers thereof, and combinations thereof. As used herein, "(meth) acrylate" and similar terms refer to acrylate and corresponding methacrylate. In addition, film-forming resins can have any one of the various functional groups, including but not limited to carboxylic acid groups, amino groups, epoxy groups, hydroxyl groups, thiol groups, carbamate groups, amide groups, urea groups, isocyanate groups (including blocked isocyanate groups), ethylenically unsaturated groups, and combinations thereof. As used herein, "ethylenically unsaturated" refers to a group with at least one carbon-to-carbon double bond. The limiting examples of ethylenically unsaturated groups include but are not limited to (meth) acrylate groups, vinyl groups, and combinations thereof.

[0016] Thermosetting coating compositions typically comprise a crosslinking agent, which may be selected from any crosslinking agent known in the art to react with the functional groups of the one or more film-forming resins used in the powder coating composition.

[0017] Non-limiting examples of crosslinking agents include phenolic resins, amino resins, epoxy resins, triglycidyl isocyanurate, guanidine, dicyandiamide, tertiary amines, imidazoles, thiols, aromatic, alicyclic and / or aliphatic anhydrides, β-hydroxy(alkyl)amides, alkylated carbamates, (meth)acrylates, salts of polycarboxylic acids with cyclic amidines, o-tolylbiguanide, isocyanates, blocked isocyanates, polyacids, anhydrides, organometallic acid-functional materials, polyamines, polyamides, aminoplasts, carbodiimides, oxazolines and / or derivatives and combinations thereof.

[0018] As described above, the binder of the powder coating composition may comprise one or more film-forming resins and, optionally, one or more crosslinking agents. A binder comprising two or more different film-forming resins may be referred to as a hybrid binder. The hybrid binder may further comprise one or more crosslinking agents comprising functional groups that react with functional groups on one or more of the film-forming resins in the hybrid binder; the functional groups produced by reacting different functional groups on different resins in the hybrid binder may further react with functional groups on functional resins and / or curing agents in the hybrid binder. In a non-limiting example, the binder comprises one or more epoxy resins and one or more polyesters and / or one or more acrylic resins, wherein the polyesters and / or acrylic resins comprise polycarboxylic acid functional groups that can react with epoxy resins, the reaction product may comprise hydroxyl functional groups, and the curing agent may comprise isocyanates or blocked isocyanates that can react with the hydroxyl functional groups of the reaction product.

[0019] Non-limiting examples of hybrid adhesives are provided in paragraphs

[0015] to

[0033] of International Publication No. WO 2018 / 187755 A1, the cited portion of which is incorporated herein by reference.

[0020] Alternatively, the binder of the powder coating composition may comprise a single film-forming resin, such as any of the film-forming resins disclosed herein, for example, an epoxy resin.

[0021] In other cases, the binder of the powder coating composition may comprise two or more film-forming resins having the same reactive functional groups. In a non-limiting example, the film-forming resin may comprise two or more epoxy-functional film-forming resins.

[0022] Based on the gross weight of the adhesive, one or more film-forming resins in any combination (such as a single resin, two or more film-forming resins with the same functional group) or as one or more film-forming resins in a mixed adhesive can be present in the adhesive in an amount of at least 10 wt % (such as at least 20 wt %, at least 30 wt % or at least 40 wt %). Based on the gross weight of the adhesive, the film-forming resin can be present in the adhesive in an amount of at most 99.9 wt % (such as at most 80 wt %, such as at most 60 wt %, such as at most 50 wt %). The film-forming resin may be present in the adhesive in an amount of 10 wt % to 99.9 wt % (such as 10 wt % to 80 wt %, such as 10 wt % to 60 wt %, such as 10 wt % to 50 wt %, such as 20 wt % to 97 wt %, such as 20 wt % to 80 wt %, such as 20 wt % to 60 wt %, such as 20 wt % to 50 wt %, such as 30 wt % to 97 wt %, such as 30 wt % to 80 wt %, such as 30 wt % to 60 wt %, such as 30 wt % to 50 wt %, such as 40 wt % to 97 wt %, such as 40 wt % to 80 wt %, such as 40 wt % to 60 wt %, such as 40 wt % to 50 wt %) based on the total weight of the adhesive.

[0023] As previously described, the powder coating compositions of the present disclosure may include an epoxy resin. Non-limiting examples of suitable epoxy-functional polymers include, but are not limited to, diglycidyl ethers of bisphenol A, polyglycidyl ethers of polyols, polyglycidyl esters of polycarboxylic acids, and combinations thereof. Non-limiting examples of suitable epoxy resins are also available from NanYa Plastics under the trade name NPES-903 and Hexion under the trade name EPON TM 2002 and EPON 2004 TM Commercially available.

[0024] The epoxy-functional polymer may have an equivalent weight of at least 200, or at least 500, or at least 675. The epoxy-functional polymer may also contain an equivalent weight of up to 5100, or up to 1000. The epoxy-functional polymer may contain an equivalent weight in the range of 200 to 5100, or 200 to 1000, or 500 to 5100, or 500 to 1000, or 675 to 5100, or 675 to 1000. As used herein, "equivalent weight" refers to the average molecular weight of the resin given in g / mol divided by the number of functional groups per molecule. Thus, the equivalent weight of the epoxy-functional polymer is determined by dividing the average molecular weight of the epoxy resin by the total number of epoxy groups and any other optional functional groups that are not epoxides. Furthermore, the average molecular weight was determined by gel permeation chromatography relative to linear polystyrene standards ranging from 800 to 900,000 Daltons as measured using a Waters 2695 Separation Module and a Waters 410 Differential Refractometer (RI detector). Tetrahydrofuran (THF) was used as the eluent at a flow rate of 1 ml min-1, and separation was performed using two PL Gel Hybrid-C (300 x 7.5 mm) columns.

[0025] It should be understood that the epoxy-functional polymer can comprise one or more types of epoxy-functional polymers. When multiple epoxy-functional polymers are used, the multiple epoxy-functional polymers can have the same or different equivalent weights. For example, a first epoxy-functional polymer can have an equivalent weight greater than the equivalent weight of a second epoxy-functional polymer. The epoxy-functional polymer can also include additional functional groups in addition to the epoxy functional groups, including but not limited to any one of the functional groups described previously. Alternatively, the epoxy-functional polymer can be free of any or all of the functional groups described previously in addition to the epoxy functional groups.

[0026] The powder coating composition may comprise, for example, a polyester, such as a hydroxyl-functional polyester. The powder composition may comprise a hybrid resin comprising a polycarboxylic acid-functional polyester and / or a polycarboxylic acid-functional acrylic resin and an epoxy resin. In each case, the polyester may comprise any suitable polyester known to those skilled in the art, and the acrylic resin may comprise any suitable acrylic resin known to those skilled in the art.

[0027] Any one of the adhesives described herein that comprises one or more resins can further comprise a cross-linking agent. Based on the gross weight of the adhesive, the cross-linking agent can be present in the adhesive in an amount of at least 0.1 % by weight (such as at least 1 % by weight, such as at least 3 % by weight, such as at least 10 % by weight, such as at least 20 % by weight). Based on the gross weight of the adhesive, the cross-linking agent can be present in the adhesive in an amount of at most 70 % by weight (such as at most 50 % by weight, such as at most 35 % by weight, such as at most 20 % by weight). The crosslinking agent may be present in the adhesive in an amount of 0.1 wt % to 70 wt % (such as 0.1 wt % to 50 wt %, such as 0.1 wt % to 35 wt %, such as 0.1 wt % to 20 wt %, such as 1 wt % to 70 wt %, such as 1 wt % to 50 wt %, such as 1 wt % to 35 wt %, such as 1 wt % to 20 wt %, such as 3 wt % to 70 wt %, such as 3 wt % to 50 wt %, such as 3 wt % to 35 wt %, such as 3 wt % to 20 wt %, such as 10 wt % to 70 wt %, such as 10 wt % to 50 wt %, such as 10 wt % to 35 wt %, such as 10 wt % to 20 wt %), based on the total weight of the adhesive.

[0028] As described above, the adhesive may optionally include a crosslinking agent, such as, but not limited to, any of those described herein. For example, when the adhesive includes an epoxy resin, suitable crosslinking agents include any of those known in the art, such as dicyandiamide, polyamines, polyamides, imidazoles, thiols, aromatic, alicyclic and / or aliphatic anhydrides, guanidines, derivatives thereof, and combinations thereof.

[0029] Non-limiting examples of binders for powder coating compositions include, essentially consisting of, or consisting of: (a) a film-forming resin, such as an epoxy resin; and (b) a crosslinking agent. The film-forming resin, such as an epoxy resin, may be present in an amount of at least 10% by weight (such as at least 20% by weight, at least 30% by weight, or at least 40% by weight) based on the total weight of the binder. The film-forming resin, such as an epoxy resin, may be present in the binder in an amount of up to 97% by weight (such as up to 80% by weight, such as up to 60% by weight, such as up to 50% by weight) based on the total weight of the binder. Based on the total weight of the adhesive, the film-forming resin (such as an epoxy resin) can be present in the adhesive in an amount of 10 wt % to 97 wt % (such as 10 wt % to 80 wt %, such as 10 wt % to 60 wt %, such as 10 wt % to 50 wt %, such as 20 wt % to 97 wt %, such as 20 wt % to 80 wt %, such as 20 wt % to 60 wt %, such as 20 wt % to 50 wt %, such as 30 wt % to 97 wt %, such as 30 wt % to 80 wt %, such as 30 wt % to 60 wt %, such as 30 wt % to 50 wt %, such as 40 wt % to 97 wt %, such as 40 wt % to 80 wt %, such as 40 wt % to 60 wt %, such as 40 wt % to 50 wt %).

[0030] Based on the total weight of the adhesive, the cross-linking agent (such as but not limited to dicyandiamide) that can react with the epoxy resin can be present in the adhesive in an amount of at least 0.1 wt % (such as at least 1 wt %, such as at least 3 wt %, such as at least 10 wt %, such as at least 20 wt %). Based on the total weight of the adhesive, the cross-linking agent can be present in the adhesive in an amount of at most 70 wt % (such as at most 50 wt %, such as at most 35 wt %, such as at most 20 wt %). The crosslinking agent may be present in the adhesive in an amount of 0.1 wt % to 70 wt % (such as 0.1 wt % to 50 wt %, such as 0.1 wt % to 35 wt %, such as 0.1 wt % to 20 wt %, such as 1 wt % to 70 wt %, such as 1 wt % to 50 wt %, such as 1 wt % to 35 wt %, such as 1 wt % to 20 wt %, such as 3 wt % to 70 wt %, such as 3 wt % to 50 wt %, such as 3 wt % to 35 wt %, such as 3 wt % to 20 wt %, such as 10 wt % to 70 wt %, such as 10 wt % to 50 wt %, such as 10 wt % to 35 wt %, such as 10 wt % to 20 wt %), based on the total weight of the adhesive.

[0031] Cross-linking agent (such as dicyandiamide) can include any stoichiometric mixing ratio of functional groups on resin (such as epoxy resin) within the above-mentioned weight ratio parameter range. The stoichiometric mixing ratio of curing agent and film-forming resin with functional groups (such as epoxy group) can be calculated by dividing the equivalent of curing agent by the equivalent of resin. For example, the equivalent of curing agent can be calculated by dividing the molecular weight of curing agent by the number of its functional groups. In non-limiting examples, the amine H equivalent of dicyandiamide can be calculated by dividing its molecular weight 84g / mole by 4 (i.e. the number of active H), resulting in an equivalent of 21. The equivalent of resin (such as epoxy resin) can be provided by supplier and / or determined by analytical techniques known to those skilled in the art or as described herein. The coating composition can include any stoichiometric mixing ratio of the functional group equivalent of curing agent and the functional group (e.g. epoxy group) equivalent of film-forming resin within the above-mentioned weight ratio parameter range. The cross-linking agent may be used in a stoichiometric mixing ratio of 0.1:1 to 10:1, such as 0.2:1 to 6.5:1, such as 0.4:1 to 3:1, such as 0.5:1 to 1.5:1, such as 0.65:1 to 1.3:1.

[0032] Crosslinking agents, such as dicyandiamide commercially available from AlzChem, can be used in any mixing ratio of moles of crosslinking agent to epoxy equivalents within the above weight ratio parameters.

[0033] The powder coating composition may comprise a resin, such as a polyester, comprising functional groups, such as hydroxyl functional groups, or a hybrid resin comprising hydroxyl functional groups derivatized as described above, and a crosslinker, such as an isocyanate reactive with the hydroxyl functional groups.

[0034] Isocyanate functional crosslinking agents can include various types of polyisocyanates. Useful polyisocyanates include aliphatic and aromatic diisocyanates and polyisocyanates of higher functionality. Non-limiting examples of suitable polyisocyanates include isophorone diisocyanate (IPDI), dicyclohexylmethane 4,4'-diisocyanate (H12MDI), cyclohexane diisocyanate (CFIDI), meta-tetramethylxylene diisocyanate (m-TMXDI), para-tetramethylxylene diisocyanate (p-TMXDI), ethylene diisocyanate, 1,2-diisocyanatopropane, 1,3-diisocyanatopropane, 1,6-diisocyanatohexane (hexamethylenediisocyanate), 1,6-diisocyanatopropane, ... methyl diisocyanate or HDI), 1,4-butene diisocyanate, lysine diisocyanate, 1,4-dicyclohexylmethane diisocyanate, toluene diisocyanate (TDI), meta-xylylenediisocyanate (MXDI) and para-xylylenediisocyanate, 4-chloro-1,3-phenylenediisocyanate, 1,5-tetrahydronaphthalene diisocyanate, 4,4'-dibenzyl diisocyanate and 1,2,4-phenylene triisocyanate, xylylenediisocyanate (XDI) and mixtures or combinations thereof.

[0035] Isocyanate cross-linking agent can comprise blocked isocyanate functional cross-linking agent." blocked isocyanate " refers to the compound with isocyanate functional group, and this isocyanate functional group has reacted with blocking agent, and this blocking agent prevents the isocyanate functional group from reacting until blocking agent is removed when being exposed to external stimulus (such as heat).The limiting examples of blocking agent comprises phenol, pyridinol, thiophenol, methyl ethyl ketone oxime, acid amides, caprolactam, imidazoles and pyrazoles.Isocyanate can also comprise uretdione isocyanate, such as uretdione internal blocked isocyanate adducts.

[0036] The binder of the powder coating composition is a binder comprising, consisting essentially of, or consisting of: (a) an epoxy resin; and (b) a crosslinker comprising dicyandiamide. The epoxy resin may be present in an amount of at least 10% by weight (such as at least 20% by weight, at least 30% by weight, or at least 40% by weight) based on the total weight of the binder. The epoxy resin may be present in an amount of up to 97% by weight (such as up to 80% by weight, such as up to 60% by weight, such as up to 50% by weight) based on the total weight of the binder. Based on the gross weight of adhesive, epoxy resin can be present in this adhesive with 10 % by weight to 97 % by weight (such as 10 % by weight to 80 % by weight, such as 10 % by weight to 60 % by weight, such as 10 % by weight to 50 % by weight, such as 20 % by weight to 97 % by weight, such as 20 % by weight to 80 % by weight, such as 20 % by weight to 60 % by weight, such as 20 % by weight to 50 % by weight, such as 30 % by weight to 97 % by weight, such as 30 % by weight to 80 % by weight, such as 30 % by weight to 60 % by weight, such as 30 % by weight to 50 % by weight, such as 40 % by weight to 97 % by weight, such as 40 % by weight to 80 % by weight, such as 40 % by weight to 60 % by weight, such as 40 % by weight to 50 % by weight).Based on the gross weight of adhesive, the cross-linking agent comprising dicyandiamide can be present in this adhesive with the amount of at least 0.1 % by weight (such as at least 1 % by weight, such as at least 3 % by weight, such as at least 10 % by weight, such as at least 20 % by weight). Based on the gross weight of tackiness agent, the cross-linking agent that comprises dicyandiamide can be present in this tackiness agent with the amount of 70 % by weight (such as 50 % by weight at the most, such as 35 % by weight at the most, such as 20 % by weight at the most).Based on the gross weight of tackiness agent, the cross-linking agent that comprises dicyandiamide can be present in this tackiness agent with the amount of 0.1 % by weight to 70 % by weight (such as 0.1 % by weight to 50 % by weight, such as 0.1 % by weight to 35 % by weight, such as 0.1 % by weight to 20 % by weight, such as 1 % by weight to 70 % by weight, such as 1 % by weight to 50 % by weight, such as 1 % by weight to 35 % by weight, such as 1 % by weight to 20 % by weight, such as 3 % by weight to 70 % by weight, such as 3 % by weight to 50 % by weight, such as 3 % by weight to 35 % by weight, such as 3 % by weight to 20 % by weight, such as 10 % by weight to 70 % by weight, such as 10 % by weight to 50 % by weight, such as 10 % by weight to 35 % by weight, such as 10 % by weight to 20 % by weight).

[0037] Based on the total weight of the composition, the film-forming component may be present in an amount of (at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 70 wt %, such as at least 75 wt %). Based on the total weight of the composition, the film-forming component may be present in an amount of not more than 79.9 wt % (such as not more than 70 wt %, such as not more than 60 wt %). Based on the total weight of the composition, the film-forming component can be present in an amount of 40 wt % to 79.9 wt % (such as 40 wt % to 70 wt %, such as 40 wt % to 60 wt %, such as 45 wt % to 79.9 wt %, such as 45 wt % to 70 wt %, such as 45 wt % to 60 wt %, such as 50 wt % to 79.9 wt %, such as 50 wt % to 70 wt %, such as 50 wt % to 60 wt %, such as 55 wt % to 79.9 wt %, such as 55 wt % to 70 wt %, such as 55 wt % to 60 wt %, such as 60 wt % to 79.9 wt %, such as 60 wt % to 70 wt %, such as 70 wt % to 79.9 wt %).

[0038] Based on the total weight of the composition, the thermosetting binder may be present in an amount greater than 40 wt % (such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 70 wt %, such as at least 75 wt %). Based on the total weight of the composition, the thermosetting binder may be present in an amount not exceeding 79.9 wt % (such as not exceeding 70 wt %, such as not exceeding 60 wt %). Based on the total weight of the composition, the thermosetting binder may be present in an amount of greater than 40 wt % to no more than 79.9 wt % (such as greater than 40 wt % to no more than 70 wt %, such as greater than 40 wt % to no more than 60 wt %, such as 45 wt % to 79.9 wt %, such as 45 wt % to 70 wt %, such as 45 wt % to 60 wt %, such as 50 wt % to 79.9 wt %, such as 50 wt % to 70 wt %, such as 50 wt % to 60 wt %, such as 55 wt % to 79.9 wt %, such as 55 wt % to 70 wt %, such as 55 wt % to 60 wt %, such as 60 wt % to 79.9 wt %, such as 60 wt % to 70 wt %, such as 70 wt % to 79.9 wt %).

[0039] Based on the gross weight of composition, thermoplastic adhesive can exist with the amount greater than 40 % by weight (such as at least 50 % by weight, such as at least 60 % by weight, such as at least 70 % by weight, such as at least 75 % by weight).Based on the gross weight of composition, thermoplastic adhesive can exist with the amount no more than 79.9 % by weight (such as no more than 70 % by weight, such as no more than 60 % by weight).Based on the gross weight of composition, thermoplastic adhesive can exist with the amount no more than 79.9 % by weight (such as no more than 40 % by weight to no more than 70 % by weight, such as no more than 40 % by weight to no more than 60 % by weight, such as 50 % by weight to 79.9 % by weight, such as 50 % by weight to 70 % by weight, such as 50 % by weight to 60 % by weight, such as 60 % by weight to 79.9 % by weight, such as 60 % by weight to 70 % by weight, such as 70 % by weight to 79.9 % by weight).

[0040] The powder coating composition of the present disclosure further comprises a phosphoric acid source. The phosphoric acid source is used as a flame retardant. As used herein, a phosphoric acid source means any phosphorus-containing material comprising phosphoric acid or its condensation or dehydration products (including oxides), or any of the aforementioned salts, esters, amides or other derivatives. The phosphoric acid source can include a variety of materials, such as, for example, phosphoric acid, monoammonium phosphate and diammonium phosphate, triphenyl phosphate, tris-(2-chloroethyl) phosphate, tris(2-chloroisopropyl) phosphate, phosphorus-containing amides (such as phosphoramide) and melamine pyrophosphate. For example, the source of phosphorus can be ammonium polyphosphate, represented by the formula (NH4) n+2 P n O 3n+1Represents, wherein n is an integer of at least 2 or n is an integer of at least 50. Based on the total weight of the composition, the composition of the present disclosure may contain a phosphoric acid source in an amount of at least 15 wt % (such as at least 18 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %). Based on the total weight of the composition, the coating composition may contain a phosphoric acid source in an amount of no more than 50 wt % (such as no more than 45 wt %, such as no more than 40 wt %, such as no more than 35 wt %, such as no more than 30 wt %, such as no more than 25 wt %). The coating composition can be in a range between any of the above values ​​(such as 15 wt % to 50 wt %, such as 15 wt % to 45 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 35 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 18 wt % to 50 wt %, such as 18 wt % to 45 wt %, such as 18 wt % to 40 wt %, such as 18 wt % to 35 wt %, such as 18 wt % to 30 wt %, such as 1 % to 45 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 35 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %, such as 25 wt % to 50 wt %, such as 25 wt % to 45 wt %, such as 25 wt % to 40 wt %, such as 25 wt % to 35 wt %, such as 25 wt % to 30 wt %, such as 25 wt % to 25 wt %).

[0041] The powder coating composition of the present disclosure further comprises a filler comprising clay, calcium carbonate, aluminum hydroxide, or clay and silica.

[0042] As used herein, the term "clay" refers to a hydrous aluminum phyllosilicate, such as kaolin clay (also known as kaolinite), montmorillonite clay, or bentonite clay.

[0043] Clay fillers can have a lamellar structure. Particles with a lamellar structure consist of hexagonally arranged sheets or plates of atoms with strong intra-sheet bonding and weak van der Waals bonding between sheets, providing low inter-sheet shear strength.

[0044] The silica may comprise any type of silica, such as crystalline or non-crystalline silica, amorphous silica, fused silica, precipitated silica, natural silica, or synthetic silica, such as those produced in a sol-gel process.

[0045] The silica and clay can be a commercially produced mixture or composite or a naturally occurring mixture or composite, such as a naturally occurring combination of particulate Neuburg silica and kaolinite. A non-limiting example of a naturally occurring combination of particulate Neuburg silica and kaolinite may have the formula SiO2 + Al2 [(OH)4Si2O5].

[0046] The filler may include additional organic or inorganic materials and may include particles of a single type of filler material or may include particles of two or more types of filler materials. That is, the filler material may include particles of a first filler material and may further include particles of at least one second (i.e., second, third, fourth, etc.) filler material that is different from the first filler material. As used herein with respect to the types of filler materials, references to "first," "second," etc., are for convenience only and do not refer to the order of addition, etc.

[0047] Other fillers may optionally be further included and selected from a variety of commonly used materials, including synthetic and natural materials, such as, but not limited to, talc, mica, diatomaceous earth, wollastonite, LAPINUS, glass, ceramics, metal oxides, hollow spheres, barium sulfate, magnesium silicate, borosilicate, calcium silicate, zinc oxide, aluminum oxide, aluminum silicate, magnesium aluminum silicate, gypsum, feldspar, synthetic inorganic and organic fillers, etc. The filler may comprise a composite material or composite particles, such as a synthetic or natural material comprising two or more materials, such as silica and clay in non-limiting examples. Other fillers include dolomite; zinc borate; magnesium carbonate; calcium oxide; calcium silicate; sodium aluminum silicate; calcium metasilicate; titanium dioxide and / or barium sulfate.

[0048] Fillers can be added to the composition separately, can be mixed during manufacture and / or can be a mixture of naturally occurring materials. Alternatively, fillers can be mixed before being added to the components to make the compositions of the present disclosure.

[0049] The filler may comprise one or more materials in any proportion. For example, the filler may comprise two materials, three materials, or four or more materials. In a filler comprising two materials, the ratio of the first filler to the second filler may be 1:99 to 99:1, such as 1:9 to 9:1, such as 1:7 to 7:1, such as 1:5 to 5:1, such as 1:3 to 3:1, such as 1:2 to 2:1, such as 1:1 to 1:3, such as 1:2 to 1:3.

[0050] The first filler may be a clay, such as kaolin clay, and the second filler may be silica.

[0051] The filler may be treated, such as but not limited to calcination, or surface treated, such as but not limited to treatment with silane or wax.

[0052] The filler material can have any particle shape or geometry. For example, the filler material can be regular or irregular in shape and can be spherical, ellipsoidal, cubic, plate-like, needle-like (elongated or fibrous), rod-like, disc-like, prism-like, flake-like, rock-like, or the like, agglomerates thereof, or any combination thereof. For example, some natural fillers may include silica having a rounded particle shape.

[0053] The particle of filler material can have as manufacturer's report on at least one dimension at least 0.01 micron (such as at least 0.1 micron, such as at least 2 microns, such as at least 10 microns) average particle diameter. The particle of filler material can have as manufacturer's report on at least one dimension for being no more than 500 microns (such as being no more than 300 microns, such as being no more than 200 microns, such as being no more than 150 microns) reported average particle diameter. The particle of filler material can have as manufacturer's report on at least one dimension for being 0.01 micron to 500 microns (such as 0.1 micron to 300 microns, such as 2 microns to 200 microns, such as 10 microns to 150 microns) reported average particle diameter. The suitable method of measuring average particle size comprises the measurement using instruments such as Quanta250FEG SEM or equivalent instruments.

[0054] Filler can comprise particle, and it comprises aggregate or the agglomerate of primary particle.Primary particle can have average primary particle diameter, such as 50 nanometers or larger, such as 100 nanometers or larger, such as 200 nanometers or larger.Filler can comprise rounded granular silicon dioxide, and comprises the aggregation primary particle that diameter is 200 nanometers.

[0055] Based on the gross weight of composition, filler can be present in said composition with the amount greater than 5 % by weight (such as at least 10 % by weight, such as greater than 10 % by weight, such as at least 15 % by weight, such as at least 20 % by weight).Based on the gross weight of composition, filler can be present in said composition with the amount no more than 70 % by weight (such as no more than 50 % by weight, such as no more than 40 % by weight, such as no more than 30 % by weight, such as no more than 25 % by weight, such as no more than 20 % by weight, such as no more than 15 % by weight). Based on the total weight of the composition, the filler can be present in an amount of from greater than 5 wt % to no more than 70 wt % (such as from greater than 5 wt % to 50 wt %, such as from greater than 5 wt % to 40 wt %, such as from greater than 5 wt % to 30 wt %, such as from greater than 5 wt % to 25 wt %, such as from greater than 5 wt % to 20 wt %, such as from greater than 5 wt % to 15 wt %, such as from 10 wt % to 70 wt %, such as from 10 wt % to 50 wt %, such as from 10 wt % to 40 wt %, such as from 10 wt % to 30 wt %, such as from 10 wt % to 25 wt %, such as from 10 wt % to 20 wt %, such as from 10 wt % to 15 wt %, such as from greater than 10 wt % to 70 wt %, such as from greater than 10 % to 50 wt %, such as greater than 10 wt % to 40 wt %, such as greater than 10 wt % to 30 wt %, such as greater than 10 wt % to 25 wt %, such as greater than 10 wt % to 20 wt %, such as greater than 10 wt % to 15 wt %, such as 15 wt % to 70 wt %, such as 15 wt % to 50 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 20 wt % to 70 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %) is present in the composition.

[0056] The clay may be present in the composition in an amount greater than 5 wt % (such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %) based on the total weight of the composition. The clay may be present in the composition in an amount not exceeding 70 wt % (such as not exceeding 50 wt %, such as not exceeding 40 wt %, such as not exceeding 30 wt %, such as not exceeding 25 wt %, such as not exceeding 20 wt %, such as not exceeding 15 wt %) based on the total weight of the composition. The clay may be present in an amount of from greater than 5 wt % to no more than 70 wt % (such as from greater than 5 wt % to 50 wt %, such as from greater than 5 wt % to 40 wt %, such as from greater than 5 wt % to 30 wt %, such as from greater than 5 wt % to 25 wt %, such as from greater than 5 wt % to 20 wt %, such as from greater than 5 wt % to 15 wt %, such as from 10 wt % to 70 wt %, such as from 10 wt % to 50 wt %, such as from 10 wt % to 40 wt %, such as from 10 wt % to 30 wt %, such as from 10 wt % to 25 wt %, such as from 10 wt % to 20 wt %, such as from 10 wt % to 15 wt %, such as from greater than 10 wt % to 70 wt %, such as from greater than 10 % to 50 wt %, such as greater than 10 wt % to 40 wt %, such as greater than 10 wt % to 30 wt %, such as greater than 10 wt % to 25 wt %, such as greater than 10 wt % to 20 wt %, such as greater than 10 wt % to 15 wt %, such as 15 wt % to 70 wt %, such as 15 wt % to 50 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 20 wt % to 70 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %) is present in the composition.

[0057] Based on the total weight of the composition, the clay and optional silica can be present in the composition in a combined amount of greater than 5 wt % (such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %). Based on the total weight of the composition, the clay and optional silica can be present in the composition in an amount of no more than 70 wt % (such as no more than 50 wt %, such as no more than 40 wt %, such as no more than 30 wt %, such as no more than 25 wt %, such as no more than 20 wt %, such as no more than 15 wt %). Based on the total weight of the composition, clay and optional silica can be present in an amount of greater than 5 wt % to 70 wt % (such as greater than 5 wt % to 50 wt %, such as greater than 5 wt % to 40 wt %, such as greater than 5 wt % to 30 wt %, such as greater than 5 wt % to 25 wt %, such as greater than 5 wt % to 20 wt %, such as greater than 5 wt % to 15 wt %, such as 10 wt % to 70 wt %, such as 10 wt % to 50 wt %, such as 10 wt % to 40 wt %, such as 10 wt % to 30 wt %, such as 10 wt % to 25 wt %, such as 10 wt % to 20 wt %, such as 10 wt % to 15 wt %, such as greater than 10 wt % to 70 wt %, such as greater than % to 40 wt %, such as greater than 10 wt % to 30 wt %, such as greater than 10 wt % to 25 wt %, such as greater than 10 wt % to 20 wt %, such as greater than 10 wt % to 15 wt %, such as 15 wt % to 70 wt %, such as 15 wt % to 50 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 20 wt % to 70 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %) in a combined amount.

[0058] Based on the gross weight of composition, calcium carbonate can be present in said composition with the amount greater than 5 % by weight (such as at least 10 % by weight, such as greater than 10 % by weight, such as at least 15 % by weight, such as at least 20 % by weight).Based on the gross weight of composition, calcium carbonate can be present in said composition with the amount that is no more than 70 % by weight (such as being no more than 50 % by weight, such as being no more than 40 % by weight, such as being no more than 30 % by weight, such as being no more than 25 % by weight, such as being no more than 20 % by weight, such as being no more than 15 % by weight). Based on the total weight of the composition, calcium carbonate can be present in an amount of greater than 5 wt % to no more than 70 wt % (such as greater than 5 wt % to 50 wt %, such as greater than 5 wt % to 40 wt %, such as greater than 5 wt % to 30 wt %, such as greater than 5 wt % to 25 wt %, such as greater than 5 wt % to 20 wt %, such as greater than 5 wt % to 15 wt %, such as 10 wt % to 70 wt %, such as 10 wt % to 50 wt %, such as 10 wt % to 40 wt %, such as 10 wt % to 30 wt %, such as 10 wt % to 25 wt %, such as 10 wt % to 20 wt %, such as 10 wt % to 15 wt %, such as greater than 10 wt % to 70 wt %, such as greater than 1 % to 30% by weight, such as 15% to 25% by weight, such as 15% to 20% by weight, such as 15% to 30% by weight, such as 15% to 25% by weight, such as 20% to 70% by weight, such as 20% to 50% by weight, such as 20% to 40% by weight, such as 20% to 30% by weight, such as 20% to 25% by weight) is present in said composition.Based on the gross weight of composition, when said composition comprised titanium dioxide with 5% by weight or larger amount, the amount of calcium carbonate can be greater than 10% by weight.

[0059] Based on the total weight of the composition, the aluminum hydroxide may be present in the composition in an amount greater than 5 wt % (such as at least 10 wt %, such as greater than 10 wt %, such as at least 15 wt %, such as at least 20 wt %). Based on the total weight of the composition, the aluminum hydroxide may be present in the composition in an amount not exceeding 70 wt % (such as not exceeding 50 wt %, such as not exceeding 40 wt %, such as not exceeding 30 wt %, such as not exceeding 25 wt %, such as not exceeding 20 wt %, such as not exceeding 15 wt %). Based on the total weight of the composition, the aluminum hydroxide can be present in an amount of from greater than 5 wt % to no more than 70 wt % (such as from greater than 5 wt % to 50 wt %, such as from greater than 5 wt % to 40 wt %, such as from greater than 5 wt % to 30 wt %, such as from greater than 5 wt % to 25 wt %, such as from greater than 5 wt % to 20 wt %, such as from greater than 5 wt % to 15 wt %, such as from 10 wt % to 70 wt %, such as from 10 wt % to 50 wt %, such as from 10 wt % to 40 wt %, such as from 10 wt % to 30 wt %, such as from 10 wt % to 25 wt %, such as from 10 wt % to 20 wt %, such as from 10 wt % to 15 wt %, such as from greater than 10 wt % to 70 wt %, such as from greater than 1 % to 30 wt %, such as greater than 10 wt % to 25 wt %, such as greater than 10 wt % to 20 wt %, such as greater than 10 wt % to 15 wt %, such as 15 wt % to 70 wt %, such as 15 wt % to 50 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 20 wt % to 70 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %) is present in the composition.

[0060] Powder coating compositions of the present disclosure may further include optional ingredients commonly used in such compositions. For example, compositions may further include curing accelerators (such as, but not limited to, imidazoles, tertiary amines, aromatic amines, urea, their derivatives and combinations), pigments (such as titanium dioxide, iron oxide, carbon black, metals and organic pigments, such as, for example, copper phthalocyanine etc.). The limiting examples of operable additives include: colorants, antioxidants, hindered amine light stabilizers, ultraviolet light absorbers and stabilizers, surfactants, flow and surface control agents, thixotropic agents, reactive diluents, driers, catalysts, reaction inhibitors, adhesion promoting components (such as acid, acid derivatives, phosphating epoxy resins and silanes, such as epoxy silanes or amine silanes) and other conventional additives well known to those skilled in the art. As used herein, " colorant " refers to any material giving composition color and / or other opacity and / or other visual effects.

[0061] The powder coating composition may comprise less than 5 wt %, such as less than 3 wt %, such as less than 1 wt %, such as less than 0.1 wt % of the organosilane, based on the total weight of the powder coating composition.

[0062] The powder coating composition may comprise less than 5 wt %, such as less than 3 wt %, such as less than 1 wt %, such as less than 0.1 wt % titanium dioxide, based on the total weight of the powder coating composition.

[0063] The powder coating composition may comprise a film-forming component comprising an epoxy resin and a curing agent, such as dicyandiamide; a phosphoric acid source comprising ammonium polyphosphate; and a filler comprising a mixture of particulate silica and kaolin clay.

[0064] The powder coating composition can be prepared by mixing the previously described adhesive, phosphoric acid source, filler material and optional additional components. The components are mixed to form a homogeneous mixture. These components can be mixed using techniques and equipment recognized in the art, such as, for example, a prism high-speed mixer. When a solid coating composition is formed, the homogeneous mixture is then melted and further mixed. The mixture can be melted using a twin-screw extruder, a single-screw extruder or similar equipment known in the art. During the melting process, the temperature is selected to melt-mix the solid homogeneous mixture without solidifying the mixture. The homogeneous mixture can be melt-mixed in a twin-screw extruder, wherein the temperature of the zone is set to 75°C to 140°C, such as 75°C to 125°C, such as 85°C to 115°C or 100°C.

[0065] After melt mixing, the mixture can be cooled and resolidified. The resolidified mixture can then be ground, for example, in a grinding process, to form a solid particulate curable powder coating composition. The resolidified mixture can be ground to any desired particle size. For example, in electrostatic coating applications, the resolidified mixture can be ground to an average particle size of at least 10 microns or at least 20 microns and at most 130 microns, as described in accordance with Beckman-Coulter LS TM 13 320 instructions described in the manual using the Beckman-Coulter LS TM 13 320 laser diffraction particle size analyzer. Further, the particle size range of the total amount of particles in the sample used to determine the average particle size may include a range of 1 micron to 200 microns, or 5 microns to 180 microns, or 10 microns to 150 microns, which range is also determined according to Beckman-Coulter LS TM 13 320 instructions described in the manual using the Beckman-Coulter LS TM The particle size was determined by 13 320 laser diffraction particle size analyzer.

[0066] The present disclosure also relates to a method of coating a substrate, the method comprising applying the powder coating composition of the present disclosure to at least a portion of the substrate. The method may further comprise at least partially curing the applied coating.

[0067] The powder coating composition can be applied by any standard method in the art, such as spraying, electrostatic spraying, fluidized bed process, etc., including robotic application. Application can be performed by precision spraying, where the composition is sprayed onto specific portions of the substrate without overspray.

[0068] After the powder coating composition is applied to the substrate, the composition can be cured or at least partially cured by heating, increasing or decreasing pressure, chemical methods (such as with moisture), or other means (such as actinic radiation), or a combination thereof. The term "actinic radiation" refers to electromagnetic radiation that can initiate a chemical reaction. Actinic radiation includes, but is not limited to, visible light, ultraviolet (UV) light, infrared radiation, X-rays, and gamma radiation. As used herein, the term "curable" or the like, as used in connection with a powder coating composition, means that at least a portion of the components comprising the powder coating composition are polymerizable and / or crosslinkable, including self-crosslinkable polymers.

[0069] The powder coating composition can be cured with heat, such as convection heating, in the range of 120°C to 260°C for 2 to 60 minutes, or in the range of 120°C to 205°C for 10 to 60 minutes, or in the range of 148°C to 204°C for 10 to 60 minutes. The powder coating composition can also be cured with infrared radiation, where the peak metal temperature can reach 204°C to 260°C in 10 to 30 seconds. The increased heat ramp achieved by infrared radiation allows for fast curing times. In some examples, the powder coating composition can be cured with infrared radiation to heat the composition in the range of 148°C to 289°C for 1 to 40 minutes, or in the range of 176°C to 275°C for 2 to 20 minutes, or in the range of 187°C to 269°C for 5 to 8 minutes.

[0070] It should be understood that the powder coating composition can be cured with multiple types of heat sources such as both convection heating and infrared radiation. For example, the powder coating composition can be partially cured with convection heating or infrared radiation, and then fully cured with a different heat source selected from convection heating and infrared radiation.

[0071] The powder coating composition can also be applied to the substrate in multiple applications. For example, a first powder coating composition can be applied to at least a portion of the substrate, and a second powder coating composition that is the same as or different from the first powder coating composition can be applied to at least a portion of the first powder coating composition. Prior to applying the second powder coating composition, the first powder coating composition can optionally be cured or at least partially cured. Alternatively, the second powder coating composition can be applied to at least a portion of the first coating composition, and the first and second powder coating compositions can then be cured together simultaneously. The powder coating composition can be cured using any of the methods described previously.

[0072] The coating formed by the powder coating composition can be applied with any desired dry film thickness. For example, when applied as a powder, the dry film thickness can be at least 2 mils (50.8 microns), such as at least 3 mils (76.2 microns), such as at least 4 mils (101.6 microns), such as at least 5 mils (127 microns), such as at least 6 mils (152.4 microns), such as at least 8 mils (203.2 microns), such as at least 10 mils (254 microns), such as at least 12 mils (304.8 microns), such as at least 20 mils (508 microns), such as at least 40 mils (1,016 microns). For example, the dry film thickness can be less than 40 mils (1,016 microns), such as less than 20 mils (508 microns), such as less than 12 mils (304.8 microns), less than 10 mils (254 microns), less than 8 mils (203.2 microns), or less than 6 mils (152.4 microns), or less than 5 mils (127 microns), or less than 4 mils (101.6 microns), or less than 3 mils (76.2 microns), or less than 2 mils (50.8 microns). The dry film thickness may be 2 to 100 mils, such as 2 to 40 mils, such as 2 to 20 mils, such as 2 to 12 mils, such as 2 to 10 mils, such as 2 to 8 mils, such as 2 to 6 mils, such as 2 to 5 mils, such as 2 to 4 mils, such as 2 to 3 mils, such as 3 to 100 mils, such as 3 to 40 mils, such as 3 to 20 mils, such as 3 to 12 mils, such as 3 to 10 mils, such as 3 to 8 mils, such as 3 to 6 mils, such as 3 to 5 mils, such as 3 to 4 mils, such as 4 to 100 mils, such as 4 to 40 mils, such as 4 to 20 mils, such as 4 to 12 mils, such as 4 to 10 mils, such as 4 to 8 mils, such as 4 to 6 mils, such as 4 to 5 mils, such as 5 to 100 mils, such as 5 The dry film thickness may be 100 microns. When applying multiple powder coating compositions, each composition can be applied individually to provide any of the previously described dry film thicknesses. For example, when applying two separate powder coating compositions, each separate powder coating composition can be applied at any of the previously described dry film thicknesses.

[0073] Optionally, the coating method may further include applying an additional coating layer below or above the powder coating composition. The additional coating layer is not limited and may comprise any suitable coating layer. For example, the coating layer of the present disclosure may comprise a first coating, and one or more additional layers may be applied over at least a portion of the first coating. Alternatively, one or more additional coating layers may be applied to a substrate, and then the powder coating composition of the present disclosure may be applied thereto to form the powder coating layer. The additional coating layer may comprise an electrodeposited coating layer.

[0074] The substrate may optionally comprise an electrodeposited coating layer and a powder coating layer applied thereto, such that the method may optionally include electrodepositing a coating from the electrodepositable coating composition onto at least a portion of the surface of the substrate to form the electrodeposited coating layer.

[0075] The electrodeposition coating layer can be electrodeposited from an electrodepositable coating composition. Any electrodepositable coating composition known in the art can be used. Particularly suitable may be those containing thermally conductive, electrically insulating fillers and / or flame retardant pigments, such as those described in International Publication No. WO 2022 / 133202 A1, paragraphs

[0045] to

[0089] , which provide non-limiting examples of mixed binders, the cited portions of which are incorporated herein by reference. Also particularly suitable may be those comprising flake pigments in a ratio of at least 0.4:1 to binder, such as those described in paragraphs

[0028] to

[0085] of International Publication No. WO 2019 / 243973 A2, paragraphs

[0010] to

[0068] of International Publication No. WO 2021 / 127327 A1, and paragraphs

[0011] to

[0016] and

[0025] to

[0205] of International Application Serial No. PCT / US2023 / 78765, the cited portions of which are incorporated herein by reference. The flake pigments may comprise flake mica pigments, flake chlorite pigments, flake serpentine pigments, flake talc pigments, and / or flake clay pigments. The flake clay pigments may comprise kaolin clay. The electrodepositable coating composition and resulting electrodeposited layer may comprise flake pigment in a ratio of flake pigment to binder of at least 0.4:1, such as at least 0.5:1, such as at least 0.6:1, such as at least 0.75:1, such as at least 1:1, such as at least 1.25:1, such as at least 1.5:1.The electrodepositable coating composition and the resulting electrodeposited layer may be prepared with a ratio of flake pigment to binder of 0.4:1 to 2:1 (such as 0.4:1 to 1.75:1, such as 0.4:1 to 1.5:1, such as 0.4:1 to 1.25:1, such as 0.4:1 to 1:1, such as 0.4:1 to 0.75:1, such as 0.4:1 to 0.7:1, such as 0.4:1 to 0.6:1, such as 0.4:1 to 0.55:1, such as 0.4:1 to 0.5:1, such as 0.5:1 to 2:1, such as 0.5:1 to 1.75:1, such as 0.5:1 to 1.50:1, such as 0.5:1 to 1.25:1, such as 0.5:1 to 1:1, such as 0.5:1 to 0.75:1, such as 0.5:1 to 0.7:1, such as 0.5:1 to 0.6:1, such as 0.5:1 to 0.55:1, Such as 0.6:1 to 2:1, such as 0.6:1 to 1.75:1, such as 0.6:1 to 1.5:1, such as 0.6:1 to 1.25:1, such as 0.6:1 to 1:1, such as 0.6:1 to 0.75:1, such as 0.6:1 to 0.7:1, such as 0.75:1 to 2:1, such as 0.75:1 to 1.75:1, such as 0.75:1 to 1.5:1, such as 0.75: 1 to 1.25:1, such as 0.75:1 to 1:1, such as 1:1 to 2:1, such as 1:1 to 1.75:1, such as 1:1 to 1.5:1, such as 1:1 to 1.25:1, such as 1.25:1 to 2:1, such as 1.25:1 to 1.75:1, such as 1.25:1 to 1.5:1, such as 1.5:1 to 2:1, such as 1.5:1 to 1.75:1) contains flake pigments.

[0076] The present disclosure also relates to a substrate comprising a coating layer deposited from any of the powder coating compositions described herein.The substrate may optionally comprise any of the additional coating layers discussed herein, such as an electrodeposited coating layer.

[0077] Alternatively, the composition of the present disclosure can be formed into a self-supporting film or sheet. The self-supporting film or sheet can be subsequently cured to form a crosslinked self-supporting film or sheet. Generally speaking, the curable composition of the present disclosure can be formed into a film or sheet by any technology well known to those skilled in the art, such as cast molding process, by impregnating a mesh with a coating, etc. The film or sheet can be cured to form a crosslinked self-supporting film or sheet, which can then be applied to a substrate. It is also within the present disclosure that, after the formation step, uncured film or sheet is applied to the substrate, and then subsequently cured to obtain a crosslinked coating layer. The film or sheet can be applied to the substrate by an adhesive. Therefore, when referring to a substrate "coated" or a similar term for the composition of the present invention herein, this includes coating by applying a film and / or sheet formed by the composition.

[0078] The powder coating composition can be applied to any substrate known in the art, such as automotive substrates, marine substrates, industrial substrates, heavy equipment, packaging substrates, wood, wood flooring and furniture, clothing, electronic products, including housings and circuit boards and including consumer electronics, such as housings for computers, notebooks, smartphones, tablet computers, televisions, gaming devices, computer equipment, computer accessories, MP3 players, etc., glass and transparencies, sports equipment including golf balls, etc. These substrates can be, for example, metallic or non-metallic. Metallic substrates include tin, steel, tin-plated steel, chrome-passivated steel, galvanized steel, aluminum, and aluminum foil. As used herein, metal sheet refers to both flat metal sheets and coiled metal sheets that are coiled, unwound for coating, and then rewound for shipment to the manufacturer. Non-metallic substrates include polymers, plastics, polyesters, polyolefins, polyamides, cellulose, polystyrene, polyacrylic acid, poly(ethylene naphthalate), polypropylene, polyethylene, nylon, EVOH, polylactic acid, other "green" polymer substrates, poly(ethylene terephthalate) ("PET"), polycarbonate, polycarbonate propylene butadiene styrene ("PC / ABS"), SMC, carbon fiber, polyamide, wood, sheet, wood composites, particle board, medium density fiberboard, cement, stone, glass, paper, cardboard, textiles, synthetic and natural leather, and the like. The substrate can be part of a structure or part of a vehicle. As used herein, "structure" refers to any part of a building, bridge, transportation infrastructure, oil rig, oil platform, water tower, transmission tower, support structure, wind turbine, wall, pier, pier, levee, dam, shipping container, truck, and any metal structure exposed to a corrosive environment. As used herein, "vehicle" refers in its broadest sense to all types of vehicles, such as, but not limited to, cars, trucks, buses, tractors, harvesters, heavy equipment, vans, golf carts, motorcycles, bicycles, rail cars, subway cars, airplanes, helicopters, watercraft of various sizes, and the like.

[0079] The substrate can be a substrate that has been treated in some way, such as to impart visual and / or color effects. For example, before applying the coating composition, the substrate can be alkaline cleaned, deoxidized, mechanically cleaned, ultrasonically cleaned, solvent wiped, roughened, plasma cleaned or etched, exposed to chemical vapor deposition, treated with an adhesion promoter, plated, anodized, annealed, coated, or any combination thereof. The substrate can be treated before applying the coating composition using any of the methods previously described, such as by immersing the substrate in a cleaning agent and / or deoxidizer bath before applying the coating composition.

[0080] It will also be understood that the substrate can be pretreated with a pretreatment composition. As used herein, a "pretreatment composition" refers to a composition that is capable of reacting with and chemically altering the substrate surface and bonding thereto to form a film that provides corrosion protection. The pretreatment composition can be an aqueous composition. Non-limiting examples of pretreatment compositions include zinc phosphate pretreatment solutions, such as those described in, for example, U.S. Patent No. 4,793,867 and U.S. Patent No. 5,588,989, or zirconium-containing pretreatment solutions, such as those described in, for example, U.S. Patent No. 7,749,368 and U.S. Patent No. 8,673,091.

[0081] The substrate may also be plated prior to application of the coating composition.As used herein, "plating" refers to the deposition of metal onto the surface of a substrate.

[0082] The substrate may comprise a three-dimensional part formed by an additive manufacturing process such as selective laser melting, electron beam melting, directed energy deposition, binder jetting, metal extrusion, etc. In an example, the three-dimensional part may be a metal and / or resin part.

[0083] The present disclosure further relates to a substrate or article coated at least in part with a powder coating composition of the present disclosure. The powder coating composition of the present disclosure can be applied to the article in any form (such as a coating composition or a crosslinked self-supporting film or sheet). When referring to a film or sheet, "applied to" and any variant thereof means that the film / sheet can be adhered to the article, such as by means of an adhesive layer, or positioned in the article or placed in the article, such as adjacent to a fixed or movable element of the article. The article can be a structure. The article can be a vehicle. The article can be a battery component or a battery, such as a lithium-ion battery or other energy storage device. For example, the coating composition of the present disclosure or a crosslinked self-supporting film or sheet can be applied to any structural element of a battery (particularly a lithium-ion battery). The battery can include an outer wall element and optionally an inner wall element defining a housing, wherein the powder coating composition can be applied at least in part to any side of the outside and / or inside of any one of the outer wall elements and / or any one of the inner wall elements (if present). For example, the outer wall and / or inner wall elements can comprise composite material, steel, aluminum and / or polycarbonate. The present coating composition can be applied to the exterior of batteries or other energy storage devices that are in contact with or near other coatings that may be flammable (such as cationic electrophoretic coatings). This can prevent or at least minimize the possibility of such coatings catching fire during a thermal runaway event. For example, the present composition in any form can be placed on the exterior wall of a battery box, including surfaces that come into contact with the body of a vehicle.

[0084] As discussed above, the substrate can include an energy storage device, such as a battery or a battery component. For example, the battery can be an electric vehicle battery, and the battery component can be an electric vehicle battery component. A "battery component" can be any component in a battery (such as a lithium-ion battery). The battery component can include, for example, electrodes, battery cells, battery housings, battery modules, battery packs, battery boxes, battery cell shells, battery pack housings, battery covers and trays, thermal management systems, battery covers, module covers, module brackets, battery side panels, battery cell housings, cooling modules, cooling pipes, heat sinks, cooling plates, bus bars, battery frames, electrical connectors, metal wires, copper or aluminum conductors or cables, or any part of a fixed electrical energy storage system. Other energy storage devices include, but are not limited to, fuel cells and / or hydrogen tanks.

[0085] According to the coating composition of the present disclosure, the outer surface of the energy storage device can be applied. For example, if applied to the battery used in the electric vehicle, the present coating composition (or the sheet / film made thereof) can confine the fire in the battery and prevent the fire from spreading to the other parts of the vehicle. For example, if an organic coating such as electrophoretic coating, primer or other coatings are deposited on the battery box, even if the present coating composition applied thereon can not prevent the coating from catching fire, it can also delay the coating from catching fire. The present coating composition can also be used on the base material with inorganic pretreatment and / or coating treatment. The heat insulation of the present coating composition can also alleviate the thermal damage of the energy storage device outside (such as other parts of a vehicle or structure).

[0086] It may be desirable to use one or more additional flame retardant materials and / or fire mitigation devices within and / or around the battery. For example, insulating and / or high-strength materials may be wrapped around the battery cells or otherwise positioned between the battery cells, or around the periphery or interior of the battery housing. Examples of such materials include fiberglass, mineral wool, silica / silica fiber, alumina, Kevlar, Nomex, calcium silicate, or calcium silicate fiber. These materials may, for example, be in sheet or other self-supporting form. Foams such as polyurethane / polyurea foams with flame retardants may also be used. Physical barriers such as heat sinks inserted between battery cells, mica sheets, aerogel blankets, and / or blankets containing mineral / glass / carbon fibers may also be used.

[0087] In order to provide flame retardant protection for articles including batteries and their users, the present disclosure also applies a powder coating composition to a portion of the article between the battery and the article near the battery. In such cases, conventional batteries or batteries according to the present disclosure can be used. For example, the article can be a mobile phone, a tablet computer or a laptop computer. Alternatively, the article can be a vehicle such as a hybrid or electric car, a bus or a truck. In such vehicles, batteries (especially lithium-ion batteries, due to their weight) are usually positioned as flat battery packs under the floor portion of the vehicle body (e.g., a car body). In such cases, the powder coating composition of the present disclosure can be applied to the floor portion of the vehicle between the battery and the vehicle body near the battery. If a thermal runaway event or battery fire occurs, the car body, especially the passenger compartment, will be protected by a coating layer comprising the powder coating composition of the present disclosure so that the battery box will resist flames, and any fire in the battery box will not spread to the passenger compartment, and the temperature rise of the passenger compartment will be limited over an extended period of time, so that passengers can safely escape the vehicle.

[0088] For the purposes of this specific embodiment, it should be understood that the present disclosure may take alternative variations and step sequences except where expressly specified to the contrary. In addition, except in any operating examples or where otherwise indicated, all numerals representing the amount of ingredients used in the specification and claims should be understood to be modified by the term "about" in all cases. Therefore, unless indicated to the contrary, the numerical parameters set forth in the following specification and the appended claims are approximate values ​​that can be changed according to the desired properties to be obtained by the present disclosure. At the very least, and not attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be interpreted in light of the number of reported significant digits and by applying usual rounding techniques.

[0089] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0090] Furthermore, it should be understood that any numerical range recited herein is intended to encompass all subranges therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, i.e., having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. When a range is given, any endpoints within those ranges and / or numbers within those ranges can be combined within the scope of the present disclosure.

[0091] As used herein, "including," "containing," and similar terms are understood in the context of this application to be synonymous with "comprising" and are therefore open-ended and do not exclude the presence of additional, undescribed or unrecited elements, materials, or ingredients. However, they also include the more restrictive terms "consisting of" and "consisting essentially of." As used herein, "consisting of" is understood in the context of this application to exclude the presence of any unspecified elements, materials, or ingredients. As used herein, "consisting essentially of" is understood in the context of this application to include the specified elements, materials, or ingredients "as well as elements, materials, or ingredients that do not materially affect the basic and novel characteristics of what is described."

[0092] In this application, unless otherwise specifically stated, the use of the singular includes the plural, and the plural encompasses the singular. For example, although reference is made herein to "a" film-forming component, "a" film-forming resin, "a" curing agent, "a" phosphoric acid source, "a" filler material, etc., combinations of these components (i.e., a plurality of these components) may be used. In addition, in this application, unless otherwise specifically stated, the use of "or" means "and / or", even though "and / or" may be explicitly used in certain circumstances.

[0093] While specific aspects of the present disclosure have been described in detail, those skilled in the art will appreciate that various modifications and alternatives to those details can be developed based on the overall teachings of the present disclosure. Therefore, the particular arrangements disclosed are intended to be illustrative only and not limiting of the scope of the present disclosure, which is to be given by the full scope of the appended claims and any and all equivalent forms thereof.

[0094] aspect

[0095] Each of the features and examples described above and their combinations may be said to be covered by the present disclosure. Therefore, the present disclosure particularly relates to (but is not limited to) the following aspects:

[0096] Aspect 1. A flame retardant powder coating composition comprising: a) a film-forming component; b) a phosphoric acid source; and c) a filler material comprising clay, calcium carbonate, aluminum hydroxide, or clay and silica.

[0097] Aspect 2. The flame retardant powder coating according to aspect 1, wherein the filler comprises clay and, optionally, silica, wherein the clay and, optionally, silica combined are present in an amount of greater than 5 wt % (such as from greater than 5 wt % to 70%, such as from greater than 5 wt % to 50%, such as from greater than 5 wt % to 40%, such as from greater than 5 wt % to 30%, such as from greater than 5 wt % to 25%, such as from greater than 5 wt % to 20%, such as from greater than 5 wt % to 15%, such as from greater than 10 wt % to 70%, such as from greater than 10 wt % to 50%, such as from greater than 10 wt % to 40%, such as from greater than 10 wt % to 30%, such as from greater than 10 wt % to 25%, such as from greater than 10 wt % to 20%, such as from greater than 1 % to 40%, such as greater than 10 weight % to 30%, such as greater than 10 weight % to 25%, such as greater than 10 weight % to 20%, such as greater than 10 weight % to 15%, such as greater than 15 weight % to 70%, such as greater than 15 weight % to 50%, such as greater than 15 weight % to 40%, such as greater than 15 weight % to 30%, such as greater than 15 weight % to 25%, such as greater than 20 weight % to 70%, such as greater than 20 weight % to 50%, such as greater than 20 weight % to 40%, such as greater than 20 weight % to 30%, such as greater than 20 weight % to 25%).

[0098] Aspect 3. The flame retardant powder coating according to aspect 1, wherein the filler comprises calcium carbonate, wherein the calcium carbonate is present in an amount of greater than 10 wt% based on the total weight of the composition when the composition contains titanium dioxide in an amount of at least 5 wt%; and / or the calcium carbonate is present in an amount of greater than 5 wt% to no more than 70 wt% (such as greater than 5 wt% to 50 wt%, such as greater than 5 wt% to 40 wt%, such as greater than 5 wt% to 30 wt%, such as greater than 5 wt% to 25 wt%, such as greater than 5 wt% to 20 wt%, such as greater than 5 wt% to 15 wt%, such as 10 wt% to 70 wt%, such as 10 wt% to 50 wt%, such as 10 wt% to 40 wt%, such as 10 wt% to 30 wt%, such as 10 wt% to 25 wt%, such as 10 wt% % to 20 wt %, such as 10 wt % to 15 wt %, such as greater than 10 wt % to 70 wt %, such as greater than 10 wt % to 50 wt %, such as greater than 10 wt % to 40 wt %, such as greater than 10 wt % to 30 wt %, such as greater than 10 wt % to 25 wt %, such as greater than 10 wt % to 20 wt %, such as greater than 10 wt % to 15 wt %, such as greater than 15 wt % to 70 wt %, such as greater than 15 wt % to 50 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 20 wt % to 70 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %).

[0099] Aspect 4. The flame retardant powder coating according to aspect 1, wherein the filler comprises aluminum hydroxide, wherein the aluminum hydroxide is present in an amount greater than 10 wt % based on the total weight of the composition when the composition comprises titanium dioxide in an amount of at least 5 wt %; and wherein the composition comprises less than 5 wt % of an organosilane.

[0100] Aspect 5. The flame retardant powder coating according to aspect 4, wherein the aluminum hydroxide is present in an amount of greater than 5 wt% to not more than 70 wt% (such as greater than 5 wt% to 50 wt%, such as greater than 5 wt% to 40 wt%, such as greater than 5 wt% to 30 wt%, such as greater than 5 wt% to 25 wt%, such as greater than 5 wt% to 20 wt%, such as greater than 5 wt% to 15 wt%, such as 10 wt% to 70 wt%, such as 10 wt% to 50 wt%, such as 10 wt% to 40 wt%, such as 10 wt% to 30 wt%, such as 10 wt% to 25 wt%, such as 10 wt% to 20 wt%, such as 10 wt% to 15 wt%, such as greater than 10 wt% to % to 40 wt%, such as greater than 10 wt% to 30 wt%, such as greater than 10 wt% to 25 wt%, such as greater than 10 wt% to 20 wt%, such as greater than 10 wt% to 15 wt%, such as greater than 15 wt% to 70 wt%, such as greater than 15 wt% to 50 wt%, such as 15 wt% to 40 wt%, such as 15 wt% to 30 wt%, such as 15 wt% to 25 wt%, such as 20 wt% to 70 wt%, such as 20 wt% to 50 wt%, such as 20 wt% to 40 wt%, such as 20 wt% to 30 wt%, such as 20 wt% to 25 wt%).

[0101] Aspect 6. The flame retardant powder coating composition according to any one of the preceding aspects, wherein the film-forming component comprises a thermosetting or thermoplastic binder present in an amount greater than 40 wt % based on the total weight of the composition.

[0102] Aspect 7. The flame retardant powder coating composition according to any one of the preceding aspects, wherein the thermosetting binder comprises a film-forming resin and a curing agent.

[0103] Aspect 8. The flame retardant powder coating composition according to aspect 7, wherein the film-forming resin comprises a (meth)acrylate resin, a polyurethane, a polyester, a polyamide, a polyether, a polysiloxane, an epoxy resin, a vinyl resin, a copolymer thereof, and a combination thereof; and the curing agent comprises a phenolic resin, an amino resin, an epoxy resin, triglycidyl isocyanurate, a guanidine, dicyandiamide, a tertiary amine, an imidazole, a thiol, an aromatic, alicyclic and / or aliphatic anhydride, a β-hydroxy(alkyl)amide, an alkylated carbamate, a (meth)acrylate, a salt of a polycarboxylic acid and a cyclic amidine, o-tolylbiguanide, a polyisocyanate, a blocked polyisocyanate, a polyacid, an anhydride, an organometallic acid functionalized material, a polyamine, a polyamide, an aminoplast, a carbodiimide, an oxazoline, and / or a derivative thereof, and a combination thereof.

[0104] Aspect 9. The flame retardant powder coating composition according to aspect 7 or 8, wherein the film-forming component comprises an epoxy resin, and the curing agent comprises dicyandiamide.

[0105] Aspect 10. The flame retardant powder coating composition according to aspects 7 to 9, wherein the film-forming resin is present in an amount of 10 wt % to 99.9 wt % (such as 10 wt % to 80 wt %, such as 10 wt % to 60 wt %, such as 10 wt % to 50 wt %, such as 20 wt % to 97 wt %, such as 20 wt % to 80 wt %, such as 20 wt % to 60 wt %, such as 20 wt % to 50 wt %, such as 30 wt % to 97 wt %, such as 30 wt % to 80 wt %, such as 30 wt % to 60 wt %, such as 30 wt % to 50 wt %, such as 40 wt % to 97 wt %, such as 40 wt % to 80 wt %, such as 40 wt % to 60 wt %, such as 40 wt % and the curing agent is present in an amount of 0.1 wt % to 70 wt % (such as 0.1 wt % to 50 wt %, such as 0.1 wt % to 35 wt %, such as 0.1 wt % to 20 wt %, such as 1 wt % to 70 wt %, such as 1 wt % to 50 wt %, such as 1 wt % to 35 wt %, such as 1 wt % to 20 wt %, such as 3 wt % to 70 wt %, such as 3 wt % to 50 wt %, such as 3 wt % to 35 wt %, such as 3 wt % to 20 wt %, such as 10 wt % to 70 wt %, such as 10 wt % to 50 wt %, such as 10 wt % to 35 wt %, such as 10 wt % to 20 wt %) based on the gross weight of the adhesive.

[0106] Aspect 11. A flame retardant powder coating composition according to any of the preceding aspects, wherein the film-forming component is present in an amount of 40 wt % to 79.9 wt % (such as 40 wt % to 70 wt %, such as 40 wt % to 60 wt %, such as 45 wt % to 79.9 wt %, such as 45 wt % to 70 wt %, such as 45 wt % to 60 wt %, such as 50 wt % to 79.9 wt %, such as 50 wt % to 70 wt %, such as 50 wt % to 60 wt %, such as 55 wt % to 79.9 wt %, such as 55 wt % to 70 wt %, such as 55 wt % to 60 wt %, such as 60 wt % to 79.9 wt %, such as 60 wt % to 70 wt %, such as 70 wt % to 79.9 wt %) based on the total weight of the composition.

[0107] Aspect 12. A flame retardant powder coating composition according to any one of the preceding aspects, wherein the film-forming component comprises a thermosetting binder present in an amount of greater than 40 wt % to no more than 79.9 wt % (such as greater than 40 wt % to no more than 70 wt %, such as greater than 40 wt % to no more than 60 wt %, such as 45 wt % to 79.9 wt %, such as 45 wt % to 70 wt %, such as 45 wt % to 60 wt %, such as 50 wt % to 79.9 wt %, such as 50 wt % to 70 wt %, such as 50 wt % to 60 wt %, such as 55 wt % to 79.9 wt %, such as 55 wt % to 70 wt %, such as 55 wt % to 60 wt %, such as 60 wt % to 79.9 wt %, such as 60 wt % to 70 wt %, such as 70 wt % to 79.9 wt %) based on the total weight of the composition.

[0108] Aspect 13. The flame retardant powder coating composition according to any one of the preceding aspects, wherein the phosphoric acid source comprises ammonium polyphosphate.

[0109] Aspect 14. The flame retardant powder coating composition according to any one of the preceding aspects, wherein the phosphoric acid source is present in an amount of 15 wt % to 50 wt % (such as 15 wt % to 45 wt %, such as 15 wt % to 40 wt %, such as 15 wt % to 35 wt %, such as 15 wt % to 30 wt %, such as 15 wt % to 25 wt %, such as 18 wt % to 50 wt %, such as 18 wt % to 45 wt %, such as 18 wt % to 40 wt %, such as 18 wt % to 35 wt %, such as 18 wt % to % to 30 wt %, such as 18 wt % to 25 wt %, such as 20 wt % to 50 wt %, such as 20 wt % to 45 wt %, such as 20 wt % to 40 wt %, such as 20 wt % to 35 wt %, such as 20 wt % to 30 wt %, such as 20 wt % to 25 wt %, such as 25 wt % to 50 wt %, such as 25 wt % to 45 wt %, such as 25 wt % to 40 wt %, such as 25 wt % to 35 wt %, such as 25 wt % to 30 wt %, such as 25 wt % to 25 wt %).

[0110] Aspect 15. The flame retardant powder coating composition according to any one of the preceding aspects, wherein the clay comprises kaolin clay and the silica comprises particulate Neuburg silica in a weight ratio of clay to silica of 1:99 to 99:1 (such as 1:9 to 9:1, such as 1:7 to 7:1, such as 1:5 to 5:1, such as 1:3 to 3:1, such as 1:2 to 2:1).

[0111] Aspect 16. A substrate coated with the flame retardant powder coating composition according to any one of the preceding aspects.

[0112] Aspect 17. The substrate according to aspect 16, wherein the substrate comprises an energy storage device, such as a fuel cell, a hydrogen tank, or a battery and / or a battery component, such as an electric vehicle battery or a battery component.

[0113] Aspect 18. The substrate according to aspect 17, wherein the battery component comprises an electrode, a battery cell, a battery housing, a battery module, a battery pack, a battery case, a battery cell housing, a battery pack housing, a battery cover and / or tray, a thermal management system, an inverter, a battery cover, a module cover, a module bracket, a battery side plate, a battery cell housing, a cooling module, a cooling tube, a heat sink, a cooling plate, a cold plate assembly, a bus bar, a battery frame, an electrical connection, a metal wire, a copper or aluminum conductor or cable, or any part of a fixed electrical energy storage system.

[0114] Aspect 19. The substrate according to any one of aspects 16 to 18, wherein the powder coating on the substrate passes a thermal runaway test.

[0115] Aspect 20. The substrate according to any of the preceding aspects 16 to 19, wherein the substrate further comprises an additional coating layer, such as a layer between the substrate and the powder coating.

[0116] Aspect 21. The substrate according to aspect 20, wherein the additional coating layer comprises an electrodeposited coating layer deposited from an electrodepositable coating composition, the electrodepositable coating composition comprising an electrodepositable binder comprising an active hydrogen-containing, ionic salt-containing film-forming polymer and a curing agent.

[0117] Aspect 22. The substrate according to aspect 21, wherein the electrodeposition coating layer further comprises flake pigments present in a ratio of flake pigment to binder of at least 0.4:1 (such as at least 0.5:1, such as at least 0.6:1, such as at least 0.75:1, such as at least 1:1, such as at least 1.25:1, such as at least 1.5:1), and / or the electrodeposition coating layer further comprises flake pigments present in a ratio of flake pigment to binder of 0.4:1 to 2:1 (such as 0.4:1 to 1.75:1, such as 0. 4:1 to 1.5:1, such as 0.4:1 to 1.25:1, such as 0.4:1 to 1:1, such as 0.4:1 to 0.75:1, such as 0.4:1 to 0.7:1, such as 0.4:1 to 0.6:1, such as 0.4:1 to 0.55:1, such as 0.4:1 to 0.5:1, such as 0.5:1 to 2:1, such as 0.5:1 to 1.75:1, such as 0.5:1 to 1.50:1, such as 0.5:1 to 1.25:1, such as 0.5:1 to 1:1, Such as 0.5:1 to 0.75:1, such as 0.5:1 to 0.7:1, such as 0.5:1 to 0.6:1, such as 0.5:1 to 0.55:1, such as 0.6:1 to 2:1, such as 0.6:1 to 1.75:1, such as 0.6:1 to 1.5:1, such as 0.6:1 to 1.25:1, such as 0.6:1 to 1:1, such as 0.6:1 to 0.75:1, such as 0.6:1 to 0.7:1, such as 0.75:1 to 2:1, such as 0.75:1 to 1.75:1, such as 0.75:1 to 1.5:1, such as 0.75:1 to 1.25:1, such as 0.75:1 to 1:1, such as 1:1 to 2:1, such as 1:1 to 1.75:1, such as 1:1 to 1.5:1, such as 1:1 to 1.25:1, such as 1.25:1 to 2:1, such as 1.25:1 to 1.75:1, such as 1.25:1 to 1.5:1, such as 1.5:1 to 2:1, such as 1.5:1 to 1.75:1).

[0118] Aspect 23. The substrate according to aspect 22, wherein the flake pigment has an average equivalent spherical diameter of at least 50 nm, or at least 0.2 micrometers, or at least 0.4 micrometers, or at least 0.6 micrometers, or at least 1 micrometer, or at least 2 micrometers, or at least 3 micrometers, or at least 4 micrometers, or at least 5 micrometers and / or no more than 25 micrometers, or no more than 15 micrometers, or no more than 10 micrometers, or no more than 5 micrometers, or no more than 3.5 micrometers, or no more than 2.5 micrometers, or no more than 1.9 micrometers, or no more than 1.5 micrometers, or no more than 1 micrometer.

[0119] Aspect 24. The substrate according to aspect 22 or 23, wherein the platelet-shaped pigment comprises a phyllosilicate pigment.

[0120] Aspect 25. The substrate according to aspect 24, wherein the phyllosilicate pigment comprises mica, chlorite, serpentine, talc, a clay material such as kaolin clay, or a combination thereof.

[0121] Aspect 26. A method of coating a substrate, the method comprising: optionally electrodepositing a coating from an electrodepositable coating composition onto at least a portion of a surface of the substrate to form an electrodeposited coating layer; and applying a flame retardant powder coating composition according to any one of Aspects 1 to 15 to at least a portion of the surface of the substrate or the electrodeposited coating layer (if present) by electrostatic spraying or fluidized bed application to form a flame retardant powder coating layer.

[0122] Aspect 27. The method according to aspect 26, wherein the electrodeposition coating layer is present and the electrodepositable coating composition comprises flake pigments in a ratio of flake pigment to binder of at least 0.4:1 (such as at least 0.5:1, such as at least 0.6:1, such as at least 0.75:1, such as at least 1:1, such as at least 1.25:1, such as at least 1.5:1), and / or the electrodepositable coating composition comprises flake pigments in a ratio of flake pigment to binder of 0.4:1 to 2:1 (such as 0.4:1 to 1.75:1). , such as 0.4:1 to 1.5:1, such as 0.4:1 to 1.25:1, such as 0.4:1 to 1:1, such as 0.4:1 to 0.75:1, such as 0.4:1 to 0.7:1, such as 0.4:1 to 0.6:1, such as 0.4:1 to 0.55:1, such as 0.4:1 to 0.5:1, such as 0.5:1 to 2:1, such as 0.5:1 to 1.75:1, such as 0.5:1 to 1.50:1, such as 0.5:1 to 1.25:1, such as 0.5:1 to 1:1, such as 0.5:1 to 0.75:1, such as 0.5:1 to 0.7:1, such as 0.5:1 to 0.6:1, such as 0.5:1 to 0.55:1, such as 0.6:1 to 2:1, such as 0.6:1 to 1.75:1, such as 0.6:1 to 1.5:1, such as 0.6:1 to 1.25:1, such as 0.6:1 to 1:1, such as 0.6:1 to 0.75:1, such as 0.6:1 to 0.7:1, such as 0.75:1 to 2:1, such as 0.75: 1 to 1.75:1, such as 0.75:1 to 1.5:1, such as 0.75:1 to 1.25:1, such as 0.75:1 to 1:1, such as 1:1 to 2:1, such as 1:1 to 1.75:1, such as 1:1 to 1.5:1, such as 1:1 to 1.25:1, such as 1.25:1 to 2:1, such as 1.25:1 to 1.75:1, such as 1.25:1 to 1.5:1, such as 1.5:1 to 2:1, such as 1.5:1 to 1.75:1) contains flake pigments.

[0123] Aspect 28. The method according to aspect 26 or 27, wherein the substrate coated by the method comprises any one of the substrates according to aspects 16 to 25.

[0124] The following examples illustrate the present disclosure, however, these examples should not be considered to limit the disclosure to their details.Unless otherwise indicated, all parts and percentages in the following examples and throughout the specification are by weight.

[0125] Examples

[0126] The following examples are intended to illustrate the present disclosure and should not be construed as limiting the present disclosure in any way.

[0127] Powder coating compositions (Powders 1 and 2) were prepared from the components listed in Table 1 (in parts by weight) according to the following steps:

[0128] Table 1 Powders 1 and 2

[0129]

[0130] For Powders 1 and 2, each of the components listed in Table 1 was weighed and mixed in a container to form a dry, uniform mixture. The mixture was then melt-mixed in an extruder. The extruded material dripped onto a chill roll to cool the mixture and resolidify it into solid fragments. The fragments were ground into a fine powder. The resulting coating compositions for each of Powders 1 and 2 were solid particulate powder coating compositions.

[0131] Powders 1 and 2 were applied using a powder spray gun to a battery cover pre-coated with an electrodeposited coating layer. The powder coatings were baked at a sufficient temperature and for a sufficient time to complete the cure. The coating materials were tested using the thermal runaway test simulation described herein. Powder 1 failed. Powder 2 passed the thermal runaway test.

[0132] Corrosion resistance testing was conducted on coated substrates comprising only an electrophoretic coating, as well as Powder 1 or 2 applied to an electrodeposited substrate. Substrates comprising Powder 1 and Powder 2 on an electrophoretic coating exhibited improved corrosion resistance compared to substrates having only an electrophoretic coating layer without a powder coating layer. Corrosion resistance can be tested according to ASTM B-117 or SAE J2334.

[0133] While specific examples of the present disclosure have been described above for purposes of illustration, it will be apparent to those skilled in the art that various changes can be made in the details of the disclosure without departing from the present disclosure as defined in the appended claims.

Claims

1. A flame retardant powder coating composition comprising: a) film-forming component; b) a source of phosphoric acid; and c) a filler material comprising clay and, optionally, silica, wherein the clay and, optionally, silica combined are present in an amount greater than 5 weight percent based on the total weight of the composition.

2. The flame retardant powder coating composition according to claim 1, wherein the film-forming component comprises a thermosetting or thermoplastic binder present in an amount greater than 40 wt. %, based on the total weight of the composition. 3 . The flame retardant powder coating composition according to claim 2 , wherein the thermosetting binder comprises a film-forming resin and a curing agent, the film-forming resin comprises an epoxy resin, and the curing agent comprises dicyandiamide.

4. A flame retardant powder coating composition according to any one of the preceding claims, wherein the film-forming component comprises an epoxy resin.

5. The flame retardant powder coating composition according to any one of the preceding claims, wherein the phosphoric acid source comprises ammonium polyphosphate.

6. The flame retardant powder coating composition according to any one of the preceding claims, wherein the phosphoric acid source is present in an amount of 15 to 50 wt. %, based on the total weight of the composition.

7. A flame retardant powder coating composition according to any one of the preceding claims, wherein the clay comprises kaolin clay and the optional silica comprises particulate silica in a clay to silica weight ratio of 1:3 to 3:

1.

8. A flame retardant powder coating composition comprising: a) film-forming component; b) a source of phosphoric acid; and c) a filler material comprising calcium carbonate, wherein the calcium carbonate is present in an amount greater than 10 wt. %, based on the total weight of the composition, when the composition comprises titanium dioxide in an amount of at least 5 wt. %.

9. A flame retardant powder coating composition comprising: a) film-forming component; b) a source of phosphoric acid; and c) a filler material comprising aluminum hydroxide, wherein the aluminum hydroxide is present in an amount greater than 10 wt % based on the total weight of the composition when the composition comprises titanium dioxide in an amount of at least 5 wt %; and wherein the composition comprises less than 5 wt % of an organosilane.

10. A substrate coated with a flame retardant powder coating composition according to any one of the preceding claims.

11. The substrate of claim 10, wherein the substrate comprises a battery and / or a battery component.

12. The substrate of claim 11, wherein the battery component comprises an electrode, a battery cell, a battery housing, a battery module, a battery pack, a battery case, a battery cell housing, a battery pack housing, a battery cover and / or tray, a thermal management system, an inverter, a battery cover, a module cover, a module bracket, a battery side plate, a battery cell housing, a cooling module, a cooling tube, a heat sink, a cooling plate, a cold plate assembly, a bus bar, a battery frame, an electrical connector, a metal wire, a copper or aluminum conductor or cable, or any part of a stationary electrical energy storage system.

13. The substrate according to any one of claims 10 to 12, wherein the powder coating passes a thermal runaway test.

14. The substrate according to any one of claims 10 to 13, further comprising an additional coating layer between the substrate and the powder coating, such as an electrodeposited coating layer.

15. The substrate of claim 14, wherein the electrodeposition coating layer further comprises flake pigments present in a flake pigment to binder ratio of at least 0.4:

1.

16. The substrate of claim 15, wherein the flake pigments have an average equivalent spherical diameter of at least 0.2 micrometers and no more than 5 micrometers.

17. The substrate of claim 15 or 16, wherein the platelet-shaped pigments comprise phyllosilicate pigments.

18. The substrate of claim 17, wherein the phyllosilicate pigment comprises mica, chlorite, serpentine, talc, kaolin clay, or combinations thereof.

19. A method of coating a substrate, the method comprising: optionally electrodepositing a coating from an electrodepositable coating composition onto at least a portion of the surface of the substrate to form an electrodeposited coating layer; as well as The flame retardant powder coating composition according to any one of claims 1 to 9 is applied to at least a portion of the surface of the substrate or to the electrodeposition coating layer, if present, by electrostatic spraying or fluidized bed application to form a flame retardant powder coating layer.

20. The method of claim 19, wherein the electrodeposited coating layer is present and the electrodepositable coating composition comprises flake pigments in a flake pigment to binder ratio of at least 0.4:1.

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