Barrier coatings having high-temperature resistance and insulating properties

Abstract

To provide: barrier coatings having high-temperature resistance and / or insulating properties that may be applied to substrates defining structures that are used in areas of combustion or areas adjacent thereto; and methods for preparing the same.SOLUTION: A barrier coating having high-temperature resistance and insulating properties includes an insulating resin, a flame retardant, and reinforcing fiber. The insulating resin includes high-consistency silicone rubber, epoxy, or a combination of high-consistency silicone rubber and epoxy. The flame retardant includes a first flame retardant and a second flame retardant, one of the first and second flame retardants including an intumescent. The intumescent includes melamine powder, expandable graphite, or a combination of melamine powder and expandable graphite. The other flame retardant includes ammonium polyphosphate. The reinforcing fiber includes aromatic polyamide, poly-paraphenyleneterephthalamide, or a combination of aromatic polyamide and poly-paraphenyleneterephthalamide.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure provides high temperature resistant, and also insulating, barrier coatings that can be applied to substrates defining structures used in or adjacent to combustion zones. [Background technology]

[0002] Materials that are heat-resistant or stain-resistant are useful in various commercial applications. Such materials can be used, for example, to prevent or reduce the burning of a structure and / or to inhibit the burning of adjacent materials, such as materials housed or contained in the structure. Depending on the different uses, the materials may need to take on different shapes and structures. It may be desirable to provide a coating that can be applied to different substrates and impart heat resistance or stain resistance without the need to modify the underlying substrate. Summary of the Invention

[0003] In various aspects, the present disclosure provides a barrier coating having high temperature resistance and insulating properties. The barrier coating can include an insulating resin, a flame retardant, and a reinforcing fiber.

[0004] In at least one exemplary embodiment, the insulating resin comprises a high-concentration silicone rubber, an epoxy, or a combination of high-concentration silicone rubber and an epoxy.

[0005] In at least one exemplary embodiment, the barrier coating comprises from about 25% to about 55% by weight of an insulating resin.

[0006] In at least one exemplary embodiment, the flame retardant includes a first flame retardant and a second flame retardant, one of the first and second flame retardants including an intumescent agent.

[0007] In at least one exemplary embodiment, the first flame retardant comprises an intumescent agent and the barrier coating comprises from about 5% by weight to about 35% by weight of the first flame retardant.

[0008] In at least one exemplary embodiment, the expansion agent includes melamine powder, expandable graphite, or a combination of melamine powder and expandable graphite.

[0009] In at least one exemplary embodiment, the barrier coating includes from about 15% by weight or more to about 55% by weight or less of a second flame retardant.

[0010] In at least one exemplary embodiment, the second flame retardant comprises ammonium polyphosphate.

[0011] In at least one exemplary embodiment, the reinforcing fibers comprise an aromatic polyamide, a polyparaphenylene terephthalamide, or a combination of an aromatic polyamide and a polyparaphenylene terephthalamide.

[0012] In at least one exemplary embodiment, the barrier coating includes from about 1% to about 10% by weight of reinforcing fibers.

[0013] In various other aspects, the present disclosure provides a method for preparing a high temperature resistant and insulating barrier coating on one or more surfaces of a substrate. The method can include contacting a barrier coating formulation with one or more surfaces of the substrate. The barrier coating formulation can include an insulating resin, a flame retardant, a reinforcing fiber, a curing agent, and a solvent.

[0014] In at least one exemplary embodiment, the insulating resin comprises a high-concentration silicone rubber, an epoxy, or a combination of high-concentration silicone rubber and an epoxy.

[0015] In at least one exemplary embodiment, the flame retardant comprises melamine powder, ammonium polyphosphate, expandable graphite, or any combination thereof.

[0016] In at least one exemplary embodiment, the curing agent includes di(2,4,dichlorobenzoyl)peroxide.

[0017] In at least one exemplary embodiment, the solvent includes methyl ethyl ketone, toluene, or a combination of methyl ethyl ketone and toluene.

[0018] In at least one exemplary embodiment, the formulation includes from about 30% to about 50% by weight of insulating resin, from about 36% to about 76% by weight of flame retardant, from about 1% to about 10% by weight of reinforcing fiber, and from about 1% to about 3% by weight of curing agent.

[0019] In at least one exemplary embodiment, the method further includes preparing a barrier coating formulation, the preparing including contacting an insulating resin with a solvent to form a flowable material, contacting a flame retardant with the flowable material, and contacting a reinforcing fiber with the flowable material.

[0020] In at least one exemplary embodiment, the solvent is a first solvent, and the preparing further comprises contacting a second solvent with the flowable material.

[0021] In at least one exemplary embodiment, the preparing further comprises contacting a curing agent with the flowable material.

[0022] In at least one exemplary embodiment, the method further includes curing the contacted barrier coating formulation, where the curing includes heating the substrate to a temperature of about 120° C. or greater for a period of about 20 minutes or greater. [Brief description of the drawings]

[0023] [Figure 1]1 is a flow chart illustrating an exemplary method of forming a formulation for use in applying a barrier coating to a substrate to provide both high temperature resistance and insulating properties, in accordance with at least one exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] It should be noted that the diagrams described herein are intended to illustrate general features of devices within the technology to describe certain embodiments. These diagrams may not precisely reflect the features of any given embodiment and are not necessarily intended to define or limit specific embodiments within the scope of the technology.

[0025] The following description of the technology is merely exemplary in nature of the subject matter, manufacture, and use of one or more inventions, and is not intended to limit the scope, application, or use of any particular invention in this application or any such other application that may be filed claiming priority to this application or to a patent issued therefrom. A non-limiting discussion of terms and phrases to aid in the understanding of the technology is provided at the end of the Detailed Description of the Invention.

[0026] The present disclosure provides a barrier coating that is resistant to high temperatures, such as upon or after exposure to 1,200° C., and also insulating. Barrier coatings according to various embodiments of the present disclosure are applied to different substrates to provide both high temperature resistance and insulating properties both before and after exposure to high temperatures. For example, barrier coatings according to various embodiments of the present disclosure are applied to substrates used to form or define structures used in examples of heat-affected systems, such as high density batteries, including lithium batteries used in automotive and aerospace products. Substrates can include, for example, aluminum, copper, plastic, or any combination thereof. The barrier coating can have an average thickness of about 100 micrometers or more to about 2,000 micrometers or less.

[0027] The barrier coating according to various embodiments of the present disclosure includes an insulating resin and a flame retardant. The barrier coating according to various embodiments of the present disclosure can also include a reinforcing fiber. The formulation according to various embodiments of the present disclosure for applying the barrier coating to different substrates to provide both high temperature resistance and insulation can include a curing agent and a solvent in addition to the insulating resin and the flame retardant, and also the reinforcing fiber. The method of preparing the barrier coating can include applying the formulation to one or more surfaces of the different substrates. The method can also include curing the applied formulation and / or preparing the formulation.

[0028] Insulating resin The barrier coating according to various embodiments of the present disclosure can include one or more insulating resins. The barrier coating according to the present disclosure can include a high-concentration silicone rubber, an epoxy resin, or a combination of high-concentration silicone rubber and an epoxy resin as one or more insulating resins. The high-concentration silicone rubber is non-conductive and insulating when charged. In at least one exemplary embodiment, the high-concentration silicone rubber can be peroxide cured.

[0029] Barrier coatings according to the present disclosure may comprise a total amount of one or more insulating resins, expressed as a weight percent of the applied barrier coating, of from about 25% to about 55% by weight, optionally from about 30% to about 50% by weight, and optionally about 41% by weight. Barrier coatings according to the present disclosure may comprise a total amount of one or more insulating resins, expressed as a volume percent of the applied barrier coating, of from about 20% to about 65% by volume, optionally from about 30% to about 50% by volume, and optionally about 32.54% by volume.

[0030] Formulations for applying a barrier coating to different substrates to impart both high temperature resistance and electrical insulation can include a total amount of one or more insulating resins, expressed as a weight percent of the applied barrier coating, of from about 8% to about 28% by weight, and optionally about 18.82% by weight. Formulations for applying a barrier coating to different substrates to impart both high temperature resistance and electrical insulation can include a total amount of one or more insulating resins, expressed as a volume percent of the applied barrier coating, of from about 5% to about 35% by volume, optionally about 8% to about 28% by volume, and optionally about 14.57% by volume.

[0031] Flame retardants Barrier coatings according to various embodiments of the present disclosure can include one or more flame retardants. Barrier coatings according to the present disclosure can include melamine powder, ammonium polyphosphate, expandable graphite, or any combination thereof. For example, in at least one exemplary embodiment, barrier coatings according to the present disclosure can include a first flame retardant (e.g., melamine powder and / or expandable graphite) and a second flame retardant (e.g., ammonium polyphosphate), where the first flame retardant is an intumescent agent that can expand as a result of heat exposure and form a protective barrier, and the second flame retardant can help prevent flames and slow combustion. The intumescent agent can expand by 50% or more (e.g., about 15-30 times) when exposed to combustion. The second flame retardant can have a relatively high nitrogen content, which allows the second flame retardant to function as a foaming agent that dilutes the oxygen concentration near the flame. For example, when exposed to heat, ammonium polyphosphate can form a carbon-rich foam at the surface that can prevent oxygen from approaching, helping to stop the combustion process and provide insulation.

[0032] The first flame retardant Barrier coatings according to the present disclosure may include, as a first flame retardant or intumescent agent, melamine powder, expandable graphite, or a combination of melamine powder and expandable graphite.

[0033] A barrier coating according to the present disclosure may comprise a total amount of a first flame retardant, expressed as a weight percent of the applied barrier coating, of from about 5% to about 35% by volume, optionally from about 8% to about 28% by volume, optionally from about 10% to about 20% by volume, and optionally about 18% by volume. A barrier coating according to the present disclosure may comprise a total amount of a first flame retardant, expressed as a volume percent of the applied barrier coating, of from about 5% to about 35% by volume, optionally from about 8% to about 28% by volume, and optionally about 10.01% by volume.

[0034] A formulation for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of a first flame retardant from about 3% to about 15% by weight, and optionally about 8.24% by weight. A formulation for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of a first flame retardant from about 3% to about 15% by volume, and optionally about 4.47% by volume.

[0035] Secondary flame retardant Barrier coatings according to the present disclosure may include ammonium polyphosphate as a second flame retardant.

[0036] Barrier coatings according to the present disclosure can include a total amount of the second flame retardant, expressed as a weight percent of the applied barrier coating, of about 15% to about 55% by volume, optionally about 28% to about 48% by volume, and optionally about 38.4% by volume. Barrier coatings according to the present disclosure can include a total amount of the second flame retardant, expressed as a volume percent of the applied barrier coating, of about 15% to about 55% by volume, optionally about 28% to about 48% by volume, and optionally about 55.87% by volume.

[0037] Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of the second flame retardant from about 5% to about 35% by volume, optionally from about 8% to about 28% by volume, and optionally about 17.65% by volume. Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of the second flame retardant from about 5% to about 35% by volume, optionally from about 8% to about 28% by volume, and optionally about 25.05% by volume.

[0038] Reinforced Fiber Barrier coatings according to various embodiments of the present disclosure can include one or more reinforcing fibers, which can help improve flow of the barrier coating and can also help provide structure to the barrier coating.

[0039] Barrier coatings according to the present disclosure may include, as reinforcing fibers, aromatic polyamides (also known as aramid fibers), polyparaphenylene terephthalamides, or combinations of aromatic polyamides and polyparaphenylene terephthalamides.

[0040] Barrier coatings according to the present disclosure, expressed as a weight percent of the applied barrier coating, may include a total amount of one or more reinforcing fibers of about 1% to about 10% by volume, optionally about 2% to about 8% by volume, optionally about 2% to about 6% by volume, optionally about 2% to about 3% by volume, and optionally about 2.6% by volume. Barrier coatings according to the present disclosure, expressed as a volume percent of the applied barrier coating, may include a total amount of one or more reinforcing fibers of about 1% to about 10% by volume, optionally about 2% to about 8% by volume, optionally about 2% to about 6% by volume, optionally about 2% to about 3% by volume, and optionally about 1.58% by volume.

[0041] Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of one or more reinforcing fibers, from about 0% to about 6%, optionally from about 0.5% to about 6%, optionally from about 0.5% to about 3%, and optionally about 1.18% by volume. Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of one or more reinforcing fibers, from about 0% to about 6%, optionally from about 0.5% to about 6%, optionally from about 0.5% to about 3%, and optionally about 0.70% by volume.

[0042] Hardener Formulations according to various embodiments of the present disclosure for applying barrier coatings to different substrates to provide both high temperature resistance and insulating properties can include one or more curing agents, which can help initiate and improve cross-linking between other components of the formulation.

[0043] Formulations for applying a barrier coating to a substrate can include di(2,4,dichlorobenzoyl) peroxide.

[0044] Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of about 0.5% to about 6% by weight, optionally about 1% to about 3% by weight, and optionally about 1.18% by weight of one or more curing agents. Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of about 0.5% to about 6% by weight, optionally about 1% to about 3% by weight, and optionally about 0.85% by weight of one or more insulating resins.

[0045] solvent Formulations according to various embodiments of the present disclosure for applying barrier coatings to different substrates to provide both high temperature resistance and insulating properties can include one or more solvents, which help ensure coatability of the formulation and barrier coating.

[0046] A formulation for applying a barrier coating to a substrate can include a solvent such as methyl ethyl ketone, toluene, or a combination of methyl ethyl ketone and toluene. For example, in at least one exemplary embodiment, a formulation according to the present disclosure can include a first solvent and a second solvent.

[0047] First Solvent A formulation for applying a barrier coating to a substrate can include methyl ethyl ketone as a first solvent.

[0048] Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of a first solvent from about 15% to about 65% by volume, optionally from about 30% to about 50% by volume, and optionally about 35.28% by volume. Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of a second solvent from about 15% to about 65% by volume, optionally from about 30% to about 50% by volume, and optionally about 37.09% by volume.

[0049] Although exemplary ranges are provided, it should be understood that the amount of first solvent included in the formulation can vary depending on the intended use of the barrier coating and / or the method of application of the formulation to form the barrier coating.

[0050] Second Solvent A formulation for applying a barrier coating to a substrate can include toluene as a second solvent.

[0051] Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a weight percent of the applied barrier coating, can include a total amount of the second solvent from about 5% to about 50% by volume, optionally from about 10% to about 30% by volume, and optionally about 17.65% by volume. Formulations for applying a barrier coating to different substrates to provide both high temperature resistance and electrical insulation, expressed as a volume percent of the applied barrier coating, can include a total amount of the second solvent from about 5% to about 50% by volume, optionally from about 10% to about 30% by volume, and optionally about 17.28% by volume.

[0052] Although exemplary ranges are provided, it should be understood that the amount of second solvent included in the formulation can vary depending on the intended use of the barrier coating and / or the method of application of the formulation to form the barrier coating.

[0053] Method of Formulation A method of forming a formulation for use in applying a barrier coating to different substrates to impart both high temperature resistance and insulating properties can include contacting an insulating resin with a first solvent to form a flowable material, and then contacting a flame retardant and also reinforcing fibers with the flowable material. A second solvent can be contacted with the flowable material simultaneously with or subsequent to contacting the flame retardant and / or reinforcing fibers. The flame retardant, reinforcing fibers, and solvent can be contacted with the flowable material at one or more intervals until incorporated. When ready for application, a curing agent can be contacted with the flowable material to form the formulation.

[0054] FIG. 1 illustrates an exemplary method 100 of forming a formulation for use in applying a barrier coating to a substrate to provide both high temperature resistance and insulating properties. As shown, the method 100 can include contacting (110) an insulating resin (e.g., high-concentration silicone rubber, peroxide cured) with a first portion of a first solvent (e.g., methyl ethyl ketone) to form a flowable material. In at least one exemplary embodiment, the contacting (110) can include dissolving the insulating resin in the first portion of the first solvent. The insulating resin can be dissolved in the first portion of the first solvent by adding the insulating resin to the first solvent and allowing the combination to stand for a period of time, after which a mixing force can be applied, for example, using a speed / spin mixer.

[0055] The method 100 includes contacting (120) a first flame retardant (e.g., melamine powder), a second flame retardant (e.g., ammonium polyphosphate), and a reinforcing fiber (e.g., aromatic polyamide) with the flowable material. In at least one exemplary embodiment, the contacting (120) can include adding the first flame retardant, the second flame retardant, and / or the reinforcing fiber in powder form to the flowable material simultaneously or sequentially. In at least one exemplary embodiment, the contacting (120) can include adding the first flame retardant, the second flame retardant, and / or the reinforcing fiber in powder form to the flowable material simultaneously or sequentially. In at least one exemplary embodiment, a mixing force can be applied between each addition, for example, using a speed / spin mixer.

[0056] The method 100 includes contacting (130) the flowable material with a second portion of the first solvent and a second solvent (e.g., toluene). Although shown after contacting (120) the first flame retardant, the second flame retardant, and the reinforcing fibers with the flowable material, it should be understood that the second portion of the first solvent and / or the second solvent can be contacted (130) with the flowable material simultaneously or sequentially with the first flame retardant, the second flame retardant, and / or the reinforcing fibers. The second portion of the first solvent can be contacted (130) with the flowable material simultaneously or sequentially with the second solvent. Although a second solvent is discussed, it should be understood that in at least one exemplary embodiment, the second solvent and associated method steps can be omitted.

[0057] The combination including the insulating resin, the first and second flame retardants, the reinforcing fibers, and the first and second solvents can be stored. Prior to application to the substrate, the method 100 includes contacting (140) a curing agent (e.g., di(2,4,dichlorobenzoyl)peroxide) with the flowable material further including the first and second flame retardants, the second portion of the first solvent, and the second solvent to form a formulation. The contacting (140) can include adding the flowable material further including the first and second flame retardants, the second portion of the first solvent, and the second solvent, and a mixing force can be applied, for example, using a speed / spin mixer.

[0058] Method of applying the formulation In at least one exemplary embodiment, the formulation can be applied to the substrate using a dip coating process. For example, the substrate (or a portion thereof) can be contacted with and immersed in the formulation. Once removed, the substrate can be allowed to dry but not cured so that a thickness check can be made. The substrate can then be contacted with and immersed in the formulation one or more times to achieve the desired thickness.

[0059] In at least one exemplary embodiment, the formulation can be applied to the substrate using a spray coating process. For example, the substrate (or a portion thereof) can be sprayed with the formulation. In at least one exemplary embodiment, the viscosity of the formulation can be adjusted, for example, by further adding a first solvent and / or a second solvent to allow for spraying. Once sprayed, the substrate can be allowed to dry but not cure so that a thickness check can be made. The substrate can then be sprayed again, if necessary, to achieve the desired thickness.

[0060] Method for curing the applied formulation to form a barrier coating Curing the formulation applied to one or more surfaces of different substrates can include heating the coated substrate (or a portion thereof) to a temperature of about 120° C. or greater for a period of about 20 minutes or greater.

[0061] Non-limiting discussion of terms The foregoing description is merely exemplary in nature and is not intended to limit the technology, its application, or uses in any manner. The broad teachings of the technology can be implemented in a variety of forms. Thus, although the technology includes specific examples, the true scope of the technology should not be limited thereto, since other modifications will become apparent upon study of the drawings, specification, and claims that follow.

[0062] Headings used herein, such as "Background" and "Abstract," as well as subheadings, are merely for general organization of the subject matter within the technology and are not intended to limit the technology or any aspect thereof. In particular, subject matter disclosed in the "Background" may include novel science and technology and may not constitute a citation of prior art. Subject matter disclosed in the "Abstract" is not an exclusive or complete technology in the entire scope of science and technology, or any embodiment thereof. Classifying or discussing materials as having particular utility within the chapters of this specification is for convenience, and no inference should be drawn that the material, when used in any given composition, must necessarily, or merely, function according to its classification herein.

[0063] It should be understood that one or more steps in the method can be performed in a different order (or simultaneously) without changing the principles of the technology. Furthermore, although each of the embodiments is described above as having certain features, any one or more of these features described with respect to any embodiment of the technology can be implemented in and / or in combination with any feature of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more of the embodiments with each other fall within the scope of the technology. For example, a component that may be A, B, C, D, or E, or a combination thereof, can also be defined as A, B, C, or a combination thereof in some embodiments.

[0064] As used herein, the phrase at least one of A, B, and C should be interpreted as meaning (A or B or C), with a non-exclusive logical OR, and not as meaning "at least one of A, at least one of B, and at least one of C."

[0065] As used herein, the words "prefer" or "preferable" refer to embodiments of the technology that provide certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Moreover, recitation of one or more preferred embodiments does not suggest that other embodiments are not useful, or is not intended to exclude other embodiments from the scope of the technology.

[0066] As used herein, the word "include" and variations thereof are intended to be non-limiting, such that a recitation of an item in a list does not exclude other similar items that may also be useful in the materials, compositions, devices, and methods of the present technology. Similarly, the words "can" and "may" and variations thereof are intended to be non-limiting, such that a recitation that an embodiment can or may include certain elements or features does not exclude other embodiments of the present technology that do not contain those elements or features.

[0067] Although the open-ended term "comprising" is used herein to describe and claim embodiments of the present technology as a synonym for non-limiting terms such as including, containing, or having, the embodiments may alternatively be described using more restrictive terms such as "consisting of" or "consisting essentially of." Thus, for any given embodiment that recites materials, components, or process steps, the present technology also specifically excludes (with respect to "consisting of") additional materials, components, or processes, and (with respect to "consisting essentially of") includes embodiments that consist of or consist essentially of such materials, components, or processes, to the exclusion of additional materials, components, or processes that affect the distinguishing properties of the embodiment, even if such additional materials, components, or processes are not expressly recited in this application. For example, a recitation of a composition or process that recites elements A, B, and C specifically contemplates embodiments that consist of, and consist essentially of, A, B, and C, excluding element D, as may be recited in the art, even if element D is not expressly recited herein as excluded. Additionally, as used herein, the term "consisting essentially of" the recited materials or components contemplates embodiments that "consist of" the recited materials or components.

[0068] As used herein, "a" and "an" indicate that "at least one" of an item is present, and, where possible, a plurality of such items may be present.

[0069] Unless otherwise specified, percentages herein are by weight.

[0070] The numerical values ​​described herein should be understood to be approximate, and should be understood to be "approximately" the described value, whether or not the value is modified with the word "about". Thus, for example, a statement that a parameter may have a value of "X" should be interpreted as the parameter may have a value of "approximately" X. The term "about" indicates that a calculation or measurement can impart a certain degree of imprecision to the value (precision to the value; approximately or reasonably close to the value; approximately, depending on the approach). If for some reason the precision imparted by "about" is not otherwise understood in this ordinary sense as understood in the art, then "about" as used herein indicates the variation that may result from the ordinary method of making, measuring, or using the material, device, or other object to which the calculation or measurement is applied.

[0071] As referred to herein, ranges include endpoints, unless otherwise specified, and include all individual values ​​and ranges sub-divided throughout the range. Thus, for example, a range of "A to B" or "about A to about B" includes A and B. Furthermore, the phrase "about A to about B" includes variations in the values ​​of A and B, which can be slightly less than A and slightly more than B, and the phrase can be read as "about A, A to B, and about B." Values ​​and ranges of values ​​for a particular parameter (such as temperature, molecular weight, weight percent, etc.) do not exclude other values ​​and ranges of values ​​useful herein.

[0072] It is also contemplated that two or more specific, exemplified values ​​for a given parameter may define endpoints for a range of values ​​that may be claimed for the parameter. For example, if a parameter X is exemplified herein as having a value A and also as having a value Z, it is contemplated that the parameter X may have a range of values ​​from about A to about Z. Similarly, the art of two or more ranges of values ​​for a parameter (whether such ranges are congruent, overlapping, or distinct) is contemplated to encompass all possible combinations of ranges for values ​​that may be claimed with the endpoints of the disclosed ranges. For example, if a parameter X is exemplified herein as having a value in the range of 1-10, or 2-9, or 3-8, it is also contemplated that the parameter X may have other ranges of values, including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

Claims

1. 1. A high temperature resistant and insulating barrier coating, comprising: An insulating resin; A flame retardant; Reinforced fibers, The barrier coating comprising:

2. 10. The barrier coating of claim 1, wherein the insulating resin comprises a high-concentration silicone rubber, an epoxy, or a combination of a high-concentration silicone rubber and an epoxy.

3. 10. The barrier coating of claim 1, wherein the barrier coating comprises from about 25% by weight to about 55% by weight of the insulating resin.

4. 10. The barrier coating of claim 1, wherein the flame retardant comprises a first flame retardant and a second flame retardant, one of the first and second flame retardants comprising an intumescent agent.

5. 5. The barrier coating of claim 4, wherein the first flame retardant comprises the intumescent agent, and the barrier coating comprises from about 5% by weight to about 35% by weight of the first flame retardant.

6. 6. The barrier coating of claim 5, wherein the expanding agent comprises melamine powder, expandable graphite, or a combination of melamine powder and expandable graphite.

7. 6. The barrier coating of claim 5, wherein the barrier coating comprises from about 15% by weight to about 55% by weight of the second flame retardant.

8. 6. The barrier coating of claim 5, wherein the second flame retardant comprises ammonium polyphosphate.

9. 10. The barrier coating of claim 1, wherein the reinforcing fibers comprise an aromatic polyamide, a polyparaphenylene terephthalamide, or a combination of an aromatic polyamide and a polyparaphenylene terephthalamide.

10. 10. The barrier coating of claim 1, wherein the barrier coating comprises from about 1% to about 10% by weight of the reinforcing fibers.

11. 1. A method for preparing a high temperature resistant and insulating barrier coating on one or more surfaces of a substrate, the method comprising: contacting the one or more substrate surfaces with a barrier coating formulation, the barrier coating formulation comprising: An insulating resin; A flame retardant; Reinforced fibers, A hardener; A solvent; The preparation method comprising:

12. The method of claim 11 , wherein the insulating resin comprises a high-concentration silicone rubber, an epoxy, or a combination of a high-concentration silicone rubber and an epoxy.

13. 12. The method of claim 11, wherein the flame retardant comprises melamine powder, ammonium polyphosphate, expandable graphite, or any combination thereof.

14. The method of claim 11 , wherein the curing agent comprises di(2,4,dichlorobenzoyl)peroxide.

15. 12. The method of claim 11, wherein the solvent comprises methyl ethyl ketone, toluene, or a combination of the methyl ethyl ketone and the toluene.

16. The formulation comprises: About 30% by weight or more and about 50% by weight or less of the insulating resin; about 36% by weight or more and about 76% by weight or less of the flame retardant; About 1% by weight or more to about 10% by weight or less of the reinforcing fibers; and from about 1% by weight to about 3% by weight of said curing agent.

17. The method further comprises preparing the barrier coating formulation, the preparing comprising: contacting the insulating resin with the solvent to form a flowable material; contacting the flame retardant with the flowable material; contacting the reinforcing fibers with the flowable material; The method of claim 11 , comprising:

18. 20. The method of claim 17, wherein the solvent is a first solvent and the preparing further comprises contacting a second solvent with the flowable material.

19. The method of claim 17 , wherein the preparing further comprises contacting the curing agent with the flowable material.

20. 12. The method of claim 11, further comprising curing the contacted barrier coating formulation, said curing comprising heating the substrate to a temperature of about 120° C. or greater for a period of about 20 minutes or greater.

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