Clear intumescent curable coatings

Abstract

The present application relates to a coating comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. The coating composition may be UV cured. The coating composition described herein may have a B rating according to EN 13501 as tested according to EN 13823 (SBI) method. Also described is a method of preparing the coating and an article containing the coating.

Description

CLEAR INTUMESCENT CURABLE COATINGSFIELD

[0001] The present disclosure relates generally to a coating comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerythritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. The coating composition described herein may have a B rating according to EN 13501 as tested according to EN 13823 (SBI) method. Also described is a method of preparing the coating and an article containing the coating.BACKGROUND

[0002] Intumescent paint or intumescent coatings (collectively, “intumescent coatings”) are generally applied to the surface of a substrate to change the flaming characteristics of the surface of the substrate, so as to retard the rapid spread of fire. In industry, intumescent coatings are applied to, for example, construction elements to increase the fire resistance limit of such elements. Intumescent coatings act to passively increase the resistance to fire. When exposed to extreme temperatures, these coatings may expand and act as an insulator. Accordingly, intumescent coating compositions are commonly used to protect structural components in buildings, including steel components, against the effects of cellulosic fire conditions.

[0003] The secret behind these coatings lies in their chemical makeup. An intumescent coating may comprise a binder and other materials in a system often “pigmented” with various intumescent ingredients that under the influence of heat that react together and soften in response to heat exposure and later hardens into an insulating material called “char” or an insulating foam. This “char”, having low thermal conductivity, which has a volume many times that of the original coating. This char greatly reduces the rate of heating experienced by the steel, thus extending the time before the steel loses its integrity and the building collapses, thereby allowing additional time for safe evacuation. For the intumescent coating to be effective, the insulating layer of char needs to have enough strength to provide fire protection and protect the substrate from damage resulting from exposure to high temperatures. Such protective layer has a relatively low thermalconductivity, thereby stopping rapid thermal conduction. Intumescent coatings are used on many structures to delay the heating effects of a fire. The coating slows the rate of temperature increase of the substrate to which the coating is applied, but also the flame spread speed. The coating thus increases the time before the flames spread in a structure, allowing people more time to flee (also known as “reaction to fire”). The extra time also makes it more likely that the fire may be extinguished or cooled with water before the structure fails.

[0004] Currently, European legislation requires Class B rated material according to European EN 13501 to be used inside certain commercial buildings, including but not limited to retail stores, hotels, and theaters. Although a “B” rating norm may be achieved by using intumescent coating, it often comes at the cost of poor appearance as well as poor chemical resistance and other properties. Manufacturers and consumers, especially those for wood coatings, have increasingly demanded improved properties and appearances for intumescent coatings similar to a 2K solvent based polyurethane coating. In view of these challenges with many conventional intumescent coatings, the need therefore remains for improved intumescent coatings having a B rating according to European EN 13501, improved clarity and appearance, chemical resistance, and other improved properties as well as other advantages.SUMMARY

[0005] The embodiments of what is described herein are not intended to be exhaustive or to limit what is provided in the claimed subject matter and disclosed in the detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of what is provided in the claimed subject matter.

[0006] A coating comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) an hydroxylated carbon source like pentaerythritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. The coating composition described herein comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) an hydroxylated carbon source like pentaerythritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof may have a B rating according to EN 13501 as tested according to EN 13823 (SBI) method.

[0007] A method of making the coating comprising 1 ) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof is disclosed herein. An article containing the coating comprising 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof is also described.

[0008] To the accomplishment of the foregoing and related ends, the following description set forth certain illustrative aspects and implementations. These are indicative of a few of the various ways in which one or more aspects may be employed. Other aspects, advantages and novel features of the disclosure will become apparent from the following detailed description when considered.DETAILED DESCRIPTION

[0009] Aspects of what is described herein are disclosed in the following description related to specific embodiments. Alternative embodiments may be devised without departing from the scope of what is described herein. Additionally, well-known embodiments of what is described herein may not be described in detail or will be omitted so as to not obscure the relevant details of what is described herein. Further, to facilitate an understanding of the description, discussion of several terms used herein follows.

[0010] As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” The embodiments described herein are not limiting, but rather exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the term “embodiment(s)” does not require that all embodiments include the discussed feature, advantage, or mode of operation.

[0011] The present disclosure relates generally to coatings that provide advantageous improvements over current coatings. It has been discovered that the use of a particular coating comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof can surprisingly lead to improved performance properties when used in a coating, namely improved appearance, improved clarity, improved chemical resistance, and a B rating according to European EN 13501 as well as other advantages. Specifically, the addition of phosphate (meth)acrylate as a monomer may improveboth flame retardancy and clarity of the coating composition. Not to be bound by theory, phosphate (meth)acrylate may act to wet the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof such that a clear intumescent flame-retardant coating may be achieved. Although phosphate (meth)acrylates are known to decrease flammability, the use of the phosphate (meth)acrylate monomer in combination with pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof provides an improvement in flame retardancy and can also provide a clearer coating than previously seen. The phosphate (meth)acrylate group is typically used to readily polymerize to provide a nonmigrating agent, but using it as a monomer in the coating composition described herein may still provide flame retardancy in addition to clearer coatings. Additionally, the use of phosphate (meth)acrylate as a monomer may improve adhesion to certain more difficult substrates such as melamine paper.

[0012] In many embodiments, a coating composition may comprise: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. The coating composition described herein may further comprise other polymers or polymer dispersions, surfactants, dispersants, defoamers, biocides, mildewcides, algaecides, thickeners, leveling agents, anti-settling agents, pH buffers, corrosion inhibitors, driers, antiskinning agents, anti -cratering agents, anti-sag agents, heat stabilizers, UV absorbers / inhibitors, UV initiators, antioxidants, wetting agents, flatteners and other inert pigments (such as titanium dioxide, dyes, clay, amorphous and surface treated silica, calcium carbonate, and the like, and combinations thereof), flow agents, and the like, and various combinations thereof as needed for a particular application. In some embodiments, the coating composition described herein coating may comprise certain additives. In many embodiments, the coating composition described herein may further comprise at least one reactive diluent, at least one non-reactive diluent, at least one drier, at least one colorant, at least one pigment, at least one dispersant, at least one wax, at least one anti-skinning agent, at least one defoamer, at least one fungicide, at least one biocide, at least one mildewcide, or combinations thereof. Other materials are also contemplated.

[0013] In many embodiments, the coating composition comprises at least one binder, wherein the binder backbone is acrylic, vinylic, epoxy, polyurethane, or combinations thereof. Other binders are also contemplated. In many embodiments, at least one binder may comprise 0% by weight to60% by weight of the coating composition. In other embodiments, at least one binder can, for example, range from 0% to 55% by weight, from 0% to 50% by weight, from 0% to 45% by weight, from 0% to 40% by weight, from 0% to 35% by weight, from 0% to 30% by weight, from 0% to 25% by weight, from 0% to 20% by weight, from 1% to 60% by weight, from 1% to 55% by weight, from 1% to 50% by weight, from 1% to 45% by weight, from 1% to 40% by weight, from 1% to 35% by weight, from 1% to 30% by weight, from 1% to 25% by weight, from 1% to 20% by weight, from 5% to 60% by weight, from 5% to 55% by weight, from 5% to 50% by weight, from 5% to 45% by weight, from 5% to 40% by weight, from 5% to 35% by weight, from 5% to 30% by weight, from 5% to 25% by weight, from 5% to 20% by weight, from 10% to 60% by weight, from 10% to 55% by weight, from 10% to 50% by weight, from 10% to 45% by weight, from 10% to 40% by weight, from 10% to 35% by weight, from 10% to 30% by weight, from 10% to 25% by weight, from 10% to 20% by weight, from 15% to 60% by weight, from 15% to 55% by weight, from 15% to 50% by weight, from 15% to 45% by weight, from 15% to 40% by weight, from 15% to 35% by weight, from 15% to 30% by weight, from 15% to 25% by weight, from 15% to 20% by weight, from 20% to 60% by weight, from 20% to 55% by weight, from 20% to 50% by weight, from 20% to 45% by weight, from 20% to 40% by weight, from 20% to 35% by weight, from 20% to 30% by weight, from 20% to 25% by weight, from 25% to 60% by weight, from 25% to 55% by weight, from 25% to 50% by weight, from 25% to 45% by weight, from 25% to 40% by weight, from 25% to 35% by weight, from 25% to 30% by weight, from 30% to 60% by weight, from 30% to 55% by weight, from 30% to 50% by weight, from 30% to 45% by weight, from 30% to 40% by weight, from 35% to 60% by weight, from 35% to 55% by weight, from 35% to 50% by weight, from 35% to 45% by weight, from 40% to 60% by weight, from 40% to 55% by weight, from 40% to 50% by weight, from 45% to 60% by weight, from 45% to 55% by weight, and from 50% to 60% by weight. Other ranges are also contemplated.

[0014] In one embodiment, the phosphate (meth)acrylate monomer in the coating composition described herein is hydroxy ethyl methacrylate phosphate. In one embodiment, the phosphate (meth)acrylate monomer in the coating composition described herein is vinyl phosphonic acid dimethyl ester (VPADME). In yet another embodiment, the phosphate (meth)acrylate monomer in the coating composition described herein is a combination of hydroxy ethyl methacrylate phosphate and vinyl phosphonic acid dimethyl ester (VPADME). In many embodiments, the phosphate (meth)acylate may comprise 5% by weight to 30% by weight of the coatingcomposition. In other embodiments, phosphate (meth)acrylate monomer can, for example, range from 5% to 25% by weight, from 5% to 20% by weight, from 5% to 15% by weight, from 10% to 30% by weight, from 10% to 25% by weight, from 10% to 20% by weight, from 15% to 30% by weight, from 15% to 20% by weight, and from 20% to 30% by weight. Other ranges are also contemplated.

[0015] In many embodiments, at least one phosphate (meth)acrylate monomer in the coating composition described herein has a hydroxyl number (also known as hydroxyl value) ranging from 300 g solid / mol to 900 g solid / mol according to ASTM E222-65T. The hydroxyl equivalent weight (OH EW) is calculated by 56100 being divided by the hydroxyl value:56100Equivalent weight (g / equivalent) = Hydroxyl valueIn some embodiments, the hydroxyl number can, for example, range from 300 g solid / mol to 800 g solid / mol, 300 g solid / mol to 700 g solid / mol, 300 g solid / mol to 600 g solid / mol, 300 g solid / mol to 500 g solid / mol, 400 g solid / mol to 900 g solid / mol, 400 g solid / mol to 800 g solid / mol, 400 g solid / mol to 700 g solid / mol, 400 g solid / mol to 600 g solid / mol, 500 g solid / mol to 900 g solid / mol, 500 g solid / mol to 800 g solid / mol, 500 g solid / mol to 700 g solid / mol, 600 g solid / mol to 900 g solid / mol, 600 g solid / mol to 800 g solid / mol, and 700 g solid / mol to 900 g solid / mol. Other ranges are also contemplated.

[0016] In many embodiments, at least one ammonium (poly)phosphate of the coating composition described herein comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.

[0017] In many embodiments, at least one ammonium (poly)phosphate comprises from 10% to 50% by weight of the coating composition. In other embodiments, at least one ammonium (poly)phosphate can, for example, range from about 10% to about 45% by weight, from about 10% to about 40% by weight, from about 10% to about 35% by weight, from about 15% to about 50% by weight, from about 15% to about 45% by weight, from about 15% to about 40% by weight, from about 20% to about 50% by weight, from about 20% to about 45% by weight, from about 20% to about 40% by weight, from about 25% to about 50% by weight, from about 25% to about 45% by weight, from about 25% to about 40% by weight, from about 30% to about 50% by weight, and from about 30% to about 45% by weight. Other ranges are also contemplated.

[0018] In many embodiments, a ratio of di pentaerythritol to ammonium (poly)phosphate ranges from 0.1:1 to 1:1. In other embodiments, a ratio of dipentaerythritol to ammonium (poly)phosphate can, for example, range from 0.15:1 to 1:1, from 0.2:1 to 1:1, from 0.25:1 to 1:1, from 0.3:1 to 1:1, from 0.35:1 to 1:1, from 0.4:1 to 1:1, from 0.45:1 to 1:1, from 0.5:1 to 1:1, from 0.55:1 to 1:1, from 0.6:1 to 1:1, from 0.65:1 to 1:1, from 0.7:1 to 1:1, from 0.75:1 to 1:1, from 0.8:1 to 1:1, from 0.85:1 to 1:1, from 0.9:1 to 1:1, from 0.1:1 to 0.9:1; from 0.15:1 to 0.9:1, from 0.2:1 to 0.9:1, from 0.25:1 to 0.9:1, from 0.3:1 to 0.9:1, from 0.35:1 to 0.9:1, from 0.4:1 to 0.9:1, from 0.45:1 to 0.9:1, from 0.5:1 to 0.9:1, from 0.55:1 to 0.9:1, from 0.6:1 to 0.9:1, from 0.65:1 to 0.9:1, from 0.7:1 to 0.9:1, from 0.75:1 to 0.9:1, from 0.8:1 to 0.9:1, from 0.1:1 to 0.8:1; from 0.15:1 to 0.8:1, from 0.2:1 to 0.8:1, from 0.25:1 to 0.8:1, from 0.3:1 to 0.8:1, from 0.35:1 to 0.8:1, from 0.4:1 to 0.8:1, from 0.45:1 to 0.8:1, from 0.5:1 to 0.8:1, from 0.55:1 to 0.8:1, from 0.6:1 to 0.8:1, from 0.65:1 to 0.8:1, from 0.7:1 to 0.8:1, from 0.75:1 to 0.8:1, from 0.1:1 to 0.7:1; from 0.15:1 to 0.7:1, from 0.2:1 to 0.7:1, from 0.25:1 to 0.7:1, from 0.3:1 to 0.7:1, from 0.35:1 to 0.7:1, from 0.4:1 to 0.7:1, from 0.45:1 to 0.7:1, from 0.5:1 to 0.7:1, from 0.55:1 to 0.7:1, from 0.6:1 to 0.7:1, from 0.65:1 to 0.7:1, from 0.1:1 to 0.6:1; from 0.15:1 to 0.6:1, from 0.2:1 to 0.6:1, from 0.25:1 to 0.6:1, from 0.3:1 to 0.6:1, from 0.35:1 to 0.6:1, from 0.4:1 to 0.6:1, from 0.45:1 to 0.6:1, from 0.5:1 to 0.6:1, from 0.55:1 to 0.6:1, from 0.5:1 to 0.6:1, and from 0.55: 1 to 0.6:1. Other ranges are also contemplated.

[0019] Further, the coating composition comprises pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. In many embodiments, pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof may comprise from 5% to 30% by weight of the coating composition. In other embodiments, pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof can, for example, range from 5% to 25% by weight, from 5% to 20% by weight, from 5% to 15% by weight, from 10% to 30% by weight, from 10% to 25% by weight, from 10% to 20% by weight, from 15% to 30% by weight, from 15% to 20% by weight, and from 20% to 30% by weight. Other ranges are also contemplated.

[0020] In one particular embodiment, the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof is post-added to the coating composition. In another embodiment, the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof may also be post-added to the coating composition where thepentaerthritol, dipentaerythritol, polysaccharides, poly hydroxylated molecules, or combinations thereof has not been added to the coating composition previously during processing.

[0021] In many embodiments, the polysaccharides may comprise starch, glycogen, amylose, amylopectin, chitosan, or combinations thereof. Further, in one embodiment, the polysaccharides used may be insoluble, soluble, partially insoluble, or partially soluble in the coating composition.

[0022] In some embodiments, various polysaccharides may be added, in addition to pentaerthyritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof, to the coating composition described herein. In a particular embodiment, the coating composition may have a ratio of 1 part polysaccharide to one part phosphate. In another embodiment, various polyhydroxilated molecules may be added, in addition to pentaerthyritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof, to the coating composition described herein. The various polyhydroxilated molecules may include but are not limited to sugars (e.g., sucrose, fructose, etc.), starch, dextrines and others. In one embodiment, the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof are insoluble or at least partially insoluble.

[0023] In many embodiments, the coating composition is clear or substantially clear. In many embodiments, the coating composition described herein is a paint, stain, varnish, clearcoat, lacquer, drying oil, or fdm. In many embodiments, the coating composition is a surface treatment, primer, intermediate coat, or topcoat. The coating composition described herein may show particular utility as clear coats, clear base coats, pigmented base coats, clear topcoats, pigmented topcoats, primers, and other coatings. In one embodiment, the coating composition is a primer, a basecoat, a topcoat, a clearcoat, or combinations thereof. In one embodiment, the coating composition is at least partially coated onto a base coat. The coating composition described herein is particularly suitable in the preparation of substrates, including but not limited to metal, plastics, wood, ceramics, cement, paper, fabric, composites, or combinations thereof. Although the coating composition described may be prepared as a clear coating, it may also be subsequently pigmented and still provide a Class B rating. In some embodiments, the coating composition described herein is a pigmented coating. In one embodiment, the coating composition described herein may be pigmentable with pigmented pastes.

[0024] In some embodiments, the coating composition is a one-part (IK) system. In other embodiments, the coating composition is a two-part (2K) system. In one embodiment, the coating composition is a three-part (3K) system. Other systems are also contemplated.

[0025] In many embodiments, the coating composition is cured by heat, UV, electron beam, radical redox, or combinations thereof. In one embodiment, the coating composition is UV curable. In many embodiments, at least one binder is UV curable. Radical redox may include methods involving the use of at least one initiator and at least one metal salt to initiate the curing reaction. In one embodiment, at least one initiator is a peroxide. In one embodiment, at least one metal salt comprises cobalt. Other curing mechanisms are contemplated.

[0026] In many embodiments, the coating composition described herein may provide a class B rating according to EN 13501-1 when tested according to EN 13823 (SBI) method. Although the coating composition described may be prepared as a clear coating, it may also be pigmented and still provide a Class B rating.

[0027] In many embodiments, the coating composition is applied to a substrate, wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof. Other substrates are also contemplated.

[0028] Also disclosed is a method of preparing the coating composition described herein comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof. Further disclosed is a method of applying the coating composition described herein comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof, wherein the steps of applying the coating comprise: 1) applying the coating composition on a substrate; and 2) curing the coating composition onto at least one substrate. The substrate may comprise metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof. The coating composition may be cured by heat, UV, electron beam, radical redox, or combinations thereof.

[0029] Also described is an article comprising: 1) a substrate having at least one major surface; and 2) the coating composition described herein and comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol,di pentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof at least partially disposed on the substrate; wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof. Other substrates are also contemplated.Experimental Results

[0030] The classification parameter F1GRA, Fire Growth RAte, provides a way to classify the fire properties of building products for the purpose of the Construction Products Derivative (CPD) and is the main parameter for classification of building products based on the SBI (Single Burning Item) test. It predicts burning behavior of a large variety of building products in reference scenarios based on real life fire scenarios. FIGRA is defined as the growth rate of the burning intensity, HRR, during a test (e.g., SBI). FIGRA is calculated as the maximum value of the function (heat release rate) / (elapsed test time) and provided as W / s.

[0031] In addition, certain threshold values of HRR and the total heat release rate must first be reached before FIGRA is calculated. Threshold values are needed to avoid that exceedingly small and early values of HRR are included as this leads to unrealistic FIGRA values. The detailed definition of FIGRA can be found in EN 13823 Single Burning Item (SBI). SBI evaluates the potential contribution of a surface lining to the development of a fire. It simulates a single burning item in a comer of a room. The test is used for the European classes Al, A2, B, C and D. For the fire classification system, the following ratings and test methods are provided below in Table 1.Table 1: Fire Ratings

[0032] Based on EN 13823, the following testing was performed below in Table 2B. Results were tested using cone calorimetry (ISO 5660, 50KW / m2) and the results converted to EN13823 norm using a mathematical model. TSP, or Total Smoke Reduction, was also measured and converted as before.Table 2A-Testing Sample CompositionSample 1 (not provided in the table) has the same formula as Sample 2 but a standard UV topcoat used to improve chemical resistances was applied on it. Sample 1 was used to assess the decrease in flame performance when overcoated with a topcoat. The samples above in Table 2A differ in the dehydrating-carbonific ratio APP / DPE ratios (Samples 3, 4, and 5) and in the HEMA-HEMA- P ratios (Samples 1 and 2).Table 2B Fire Testing

[0033] Sample 1 has the same formula as Sample 2, but is overcoated with a standard UV topcoat used to improve chemical resistances. Based on the results from Table 2, Samples 2, 3, and 5 achieved the Class B rating similar to the control, which is a standard solventborne system that is an SBI certified class B SB system .

[0034] Table 3 Performance Testing Results-ClarityFor the coatings examples provided above in Table 3, lower haze, higher transmittance the better, and higher clarity are preferred. After UV curing, samples were run according to ASTM D 1003 and ASTM D 1044. The samples in Table 3 are provided in increasing amount of acidic methacrylate adhesion promoter (a phosphate (meth)acrylate monomer) to show the correlation. For Table 3, there is a positive correlation between the amount of phosphate (meth)acrylate monomer (specifically phosphate acrylate in these examples) and clarity. Further, there is also a positive correlation between the amount of phosphate (meth)acrylate monomer (specificallyphosphate acrylate in these examples) and flame retardancy. However, there is also a decrease in reactivity as the amount of phosphate (meth)acrylate monomer (specifically phosphate acrylate in these examples) increases, up to the point the energy required becomes too high.Embodiments

[0035] The following embodiments are contemplated. All combinations of features and embodiments are contemplated.

[0036] Embodiment 1 : A coating composition comprising: 1) at least one binder; 2) at least one phosphate (meth)acrylate monomer; 3) ammonium (poly)phosphate; and 4) pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof.

[0037] Embodiment 2: An embodiment of Embodiment 1, wherein at least one binder is acrylic, epoxy, polyurethane, or combinations thereof.

[0038] Embodiment 3: An embodiment of any of Embodiments 1-2, wherein the phosphate (meth)acrylate monomer is hydroxy ethyl methacrylate phosphate.

[0039] Embodiment 4: An embodiment of any of Embodiments 1-3, wherein the at least one phosphate (meth)acrylate monomer has a hydroxyl number ranging from 300 g solid / mol to 900 g solid / mol according to ASTM E222-65T.

[0040] Embodiment 5: An embodiment of any of Embodiments 1-4, wherein at least one ammonium (poly)phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.

[0041] Embodiment 6: An embodiment of any of Embodiments 1-5, wherein a ratio of dipentaerythritol ranges to ammonium (poly)phosphate from 0.1 :1 to 1: 1.

[0042] Embodiment 7: An embodiment of any of Embodiments 1-6, wherein the coating composition is clear or substantially clear.

[0043] Embodiment 8: An embodiment of any of Embodiments 1-7, wherein the coating composition is a primer, a basecoat, a topcoat, a clearcoat, or combinations thereof.

[0044] Embodiment 9: An embodiment of any of Embodiments 1-8, wherein the coating composition is a one-part system.

[0045] Embodiment 10: An embodiment of any of Embodiments 1-8, wherein the coating composition is a two-part system.

[0046] Embodiment 11 : An embodiment of any of Embodiments 1-10, wherein the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof is postadded to the coating composition.

[0047] Embodiment 12: An embodiment of any of Embodiments 1-11, wherein the coating composition is cured by heat, UV, electron beam, radical redox, or combinations thereof

[0048] Embodiment 13: An embodiment of any of Embodiments 1-12, wherein the coating composition has a B rating according to EN 13501 as tested according to EN 13823 (SBI) method.

[0049] Embodiment 14: An embodiment of any of Embodiments 1-13, wherein the coating composition is applied to a substrate, wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof.

[0050] Embodiment 15: A method of preparing the coating composition of any of Embodiments 1-14.

[0051] Embodiment 16: An article comprising: 1) a substrate having at least one major surface; and 2) the coating composition of any of Embodiments 1-14 at least partially disposed on the substrate; wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof.

[0052] What has been described above includes examples of the claimed subject matter. All details and any described modifications in connection with the Background and Detailed Description are within the spirit and scope of the claimed subject matter will be readily apparent to those of skill in the art. In addition, it should be understood that aspects of the claimed subject matter and portions of various embodiments and various features recited below and / or in the appended claims may be combined or interchanged either in whole or in part. In the foregoing descriptions of the various embodiments, those embodiments which refer to another embodiment may be appropriately combined with other embodiments as will be appreciated by one of skill in the art. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the claimed subject matter, realizing that many further combinations and permutations of the claimed subject matter are possible. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims.Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

Claims

What is claimed is:

1. A coating composition comprising: at least one binder; at least one phosphate (meth)acrylate monomer; ammonium (poly)phosphate; and pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof.

2. The coating composition of Claim 1, wherein at least one binder is acrylic, epoxy, polyurethane, or combinations thereof.

3. The coating composition of any of Claims 1-2, wherein the phosphate (meth)acrylate monomer is hydroxy ethyl methacrylate phosphate.

4. The coating composition of any of Claims 1-3, wherein the at least one phosphate (meth)acrylate monomer has a hydroxyl number ranging from 300 g solid / mol to 900 g solid / mol according to ASTM E222-65T.

5. The coating composition of any of Claims 1-4, wherein at least one ammonium (poly)phosphate comprises monoammonium phosphate, diammonium phosphate, ammonium polyphosphate, or combinations thereof.

6. The coating composition of any of Claims 1-5, wherein a ratio of dipentaerythritol to ammonium (poly)phosphate ranges from 0.1 : 1 to 1 : 1.

7. The coating composition of any of Claims 1-6, wherein the coating composition is clear or substantially clear.

8. The coating composition of any of Claims 1-7, wherein the coating composition is a primer, a basecoat, a topcoat, a clearcoat, or combinations thereof.

9. The coating composition of any of Claims 1-8, wherein the coating composition is a one- part system.

10. The coating composition of any of Claims 1-8, wherein the coating composition is a two- part system.

11. The coating composition of any of Claims 1-10, wherein the pentaerthritol, dipentaerythritol, polysaccharides, polyhydroxylated molecules, or combinations thereof is post-added to the coating composition.

12. The coating composition of any of Claims 1-11, wherein the coating composition is cured by heat, UV, electron beam, radical redox, or combinations thereof.

13. The coating composition of any of Claims 1-12, wherein the coating composition has a B rating according to EN 13501 as tested according to EN 13823 (SBI) method.

14. The coating composition of any of Claims 1-13, wherein the coating composition is applied to a substrate, wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof.

15. A method of preparing the coating composition of any of Claims 1-14.

16. An article comprising: a substrate having at least one major surface; and the coating composition of any of Claims 1-14 at least partially disposed on the substrate; wherein the substrate comprises to metal, plastics, wood, wood composites, glass, ceramics, paper, leather, cement, concrete, or combinations thereof.

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