Coatings having Anti-blast properties

Abstract

Coatings having anti-blast properties are disclosed, as are methods for using such compositions and substrates coated with same.

Description

COATINGS HAVING ANTI-BLAST PROPERTIESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 701,898 filed October 1, 2024; U.S. Provisional Patent Application No. 63 / 646,037 filed May 13, 2024; U.S. Provisional Patent Application No. 63 / 658,641 filed June 11, 2024; and U.S. Provisional Patent Application No. 63 / 660,029 filed June 14, 2024, all of which are incorporated herein by reference.FIELD

[0002] The present disclosure is directed to coating compositions having anti-blast properties, to a method for using the compositions to coat a substrate, to a substrate coated with said composition, and to an article comprising said substrate, including energy storage devices.BACKGROUND

[0003] Protective coatings have been used for a variety of structural applications to protect against both cellulosic and hydrocarbon fires. Such coatings offer protection by imparting fire resistance to the coated substrate. Numerous substrates may benefit from being coated with such coatings, including structural building components used, for example, in commercial and transportation infrastructures like hotels, airports, concert halls or offshore sites, chemical plants, oil rigs, and the like, that would be exposed to extreme heat in the case of fire. Energy storage devices, such as batteries, including lithium-ion batteries, may also be exposed to such intense heat. Such energy storage devices are vulnerable to thermal runaways during which heat and gas are rapidly discharged and a fire hazard is created. In addition to high temperatures, these devices may be subject to high blast ejecta from the battery cells. Improved protective coatings, including those having improved anti-blast properties for energy storage devices, are therefore desired.SUMMARY

[0004] The present disclosure is directed to a coating composition comprising a) a filmforming component; b) a silicon component; and c) a phyllosilicate component; wherein b and c are different, and wherein a coating layer deposited from the composition, when cured to a dry film thickness of 2 mm + / - 0.5 mm, has anti-blast properties.

[0005] Methods of using the coating compositions according to the present disclosure and / or a film and / or sheet formed therefrom to coat a substrate, and substrates coated thereby, as well as articles comprising such coated substrates, are also within the scope of the present disclosure, including vehicles, structures, batteries, and other energy storage devices.DETAILED DESCRIPTION

[0006] The present disclosure is directed to a coating composition comprising a) a filmforming component; b) a silicon component; and c) a phyllosilicate component; wherein b and c are different, and wherein a coating layer deposited from the composition, when cured to a dry film thickness of 2 mm + / - 0.5 mm, has anti-blast properties. The present coating may be described herein in terms of a coating composition, which will be understood as referring to an uncured or unhardened mixture of coating components. The coating composition can be deposited and cured to form a coating or coating layer (used interchangeably herein) or can be formed into a self-supporting film and / or sheet. “Cure”, “harden,” and like terms may be used inter-changeably herein and refer to the ability of at least a portion of the polymerizable and / or crosslinkable components to undergo a reaction.

[0007] The present coating compositions can be used to form a coating layer having antiblast properties. “Anti-blast properties” and like terms refer to coatings that, when cured to a dry film thickness of 2 mm + / - 0.5 mm, pass the Blast Test. The “Blast Test” is performed by applying the coating composition to 150 x 75 x 0.8 mm electrocoated aluminum panels with airless spray application, and curing the coating by heating at 90°C for at least two hours to a dry film thickness of 2 mm + / - 0.5 mm. The coated side of the panel is fixed at 5 cm away from a stage fountain device. The stage fountain device is set to deliver 230-250 g of net explosive mass over 18-25 seconds. A thermocouple in full contact with the surface measures the backside temperature of the panel. A coating layer passes the Blast Test or has “anti-blast properties” if the backside temperature of the panel does not exceed 300°C; when the backside temperature is 300°C or less, the electrocoat does not catch fire. For purposes of the Blast Test, the ecoat deposited on the panel is a standard ecoat; that is, the ecoat is not a fire-resistant ecoat as described below. Also, for purposes of the Blast Test the coating layer is deposited so as to have a DFT of 2 mm + / - 0.5 mm, but it will be understood that both thinner (i.e. lower than 1.5 mm) and thicker (i.e. greater than 2.5 mm) coating layers may also pass the Blast Test and therefore also impart anti-blast properties to the substrates they coat.

[0008] The coating compositions according to the present disclosure are particularly suitable for the surfaces of energy storage devices, especially the inside surfaces of such devices, and most especially the inside lid of such devices. If applied to a battery used in an electric vehicle, the present coatings (and / or sheets / films made from the same) may contain or keep within the battery blast ejecta from the battery, such as the battery cells; this serves to keep the heat and fire from spreading to other parts of the vehicle. For example, the present coatings may retard, if not prevent, flammable materials in the car from catching fire. The anti-blast properties of the present coatings (as indicated by passing the Blast Test) may also mitigate heat damage outside of the energy storage device, such as other parts of a vehicle or structure, and / or may mitigate the chance of igniting elements outside of the energy storage device by keeping heat and blast particles within the battery confines.

[0009] The coating compositions comprise a film-forming component. “Film-forming” means that the composition, upon hardening and / or curing, can form a continuous film on a surface. A film-forming component may include, for example, a film-forming resin and a crosslinker therefore. Film-forming resin, and base may all be used interchangeably herein. Crosslinker, curing agent and hardener may all be used interchangeably herein. Any filmforming resin can be used according to the present disclosure. Such a resin can react with itself, that is, undergo a self-crosslinking reaction, or can react with a crosslinker to form a film. Such reactions may occur at ambient (i.e. 20°C + / - 5) or elevated temperature (i.e., greater than 50°C). The coating compositions of the present disclosure may specifically exclude electrodepo sitable coating compositions or “ecoats”; that is, the coating composition may not be an electrodepositable coating composition. An electrodepositable coating composition comprises an ionic salt group-containing film-forming component that allows the composition to be deposited onto a substrate by electrodeposition.

[0010] Any suitable resin or combination of resins can be used in the film-forming component, including, but not limited to, epoxy resins, acrylic resins, siloxane resins, polysiloxane resins, silane resins, polyurethane resins, polyurea resins, polyvinyl resins, phenolic resins, urea-formaldehyde resins, polyimide resins, melamine resins, polyester resins, and cyanate resins. Among these resins, epoxy resins, acrylic resins, and / or polyurethane resins are particularly suitable, as are resins comprising siloxanes and / or silanes, which contribute to the silicon component as described below.

[0011] Film-forming resins used according to the present disclosure contain one or more functional groups that cither react with each other or with the functional groups on the crosslinker. Examples of suitable functional groups include, for example, ketone, hydrazide, carbodiimide, oxazoline, epoxy, amine, vinyl, amide, carbamate, urea, mercaptan, carboxylic acid, (meth)acryloyl, isocyanate, alkoxysilyl, anhydride, hydroxyl, and alkoxy functional groups, and combinations thereof.

[0012] Suitable functional groups that are capable of reacting with each other include, for example, N-methylolamide groups; silane groups having silicon bonded hydrolysable or condensable groups, for example chloro, hydroxy, alkoxy, acetoxy and / or ketoxy groups; ethylenically unsaturated fatty acid groups for example capable of oxidative drying; azomethine groups; azetidine groups; and groups capable of a thermally reversible Diels-Alder reaction, for example furan / maleimide. If the resin contains functional groups that can react with each other, the resin is considered self-crosslinking, and the presence of a curing agent may not be necessary in the present compositions.

[0013] The resin may contain a combination of functional groups that can react with each other (self-crosslinking) and functional groups that are reactive with the functional groups of a curing agent. In such cases, a curing agent may be present; upon cure, two crosslinking mechanisms will occur: (i) the reaction between functional groups on the crosslinker and the resin and (ii) the self-crosslinking reaction of the resin itself.

[0014] Suitable epoxy resins for use in the present disclosure comprise at least one polyepoxide. The polyepoxide typically has more than one 1,2-epoxy group. The calculated epoxy equivalent weight of the polyepoxide may range from 80 to 6000 g / eq, such as 100 to 700 g / eq. Epoxy compounds can be saturated or unsaturated, cyclic, aliphatic, alicyclic, aromatic or heterocyclic. They may comprise substituent(s), such as halogen, hydroxy, and ether groups.

[0015] Examples of suitable polyepoxides are those having more than one, usually two, 1,2-epoxy equivalents, i.e., polyepoxides having two epoxy groups per molecule on average. The most commonly used poly epoxides are, for example, polyglycidyl ethers of polyphenols, such as 2,2-bis(4-hydroxyphenyl)propane (bisphenol A), resorcinol, hydroquinone, benzenedimethanol, phloroglucinol, bisphenol F, and catechol; or polyglycidyl ether of polyols, such as alicyclic polyols, such as 1,2-cyclohexane diol, 1,4-cyclohexane diol, 2,2-bis(4-hydroxycyclohexyl)propane, 1 , 1 -bis(4-hydroxycyclohexyl)ethane, 2-methyl- 1 , 1 -bis(4-hydroxycyclohexyl)propane, 2,2-bis(4- hydroxy-3-tert-butylcyclohexyl)propane, 1,3-bis(hydroxymcthyl)cyclohcxanc and l,2-bis(hydroxymcthyl)cyclohcxanc. The examples of aliphatic polyols include, in particular, trihydroxymethylpentane diol, ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propylene glycol, 1 ,4-butyleneglycol, 1,5-pentanediol, 1,2,6-hexanetriol, cyclohexanedimethanol, glycerol, trimethylolpropane, hydrogenated bisphenol A, hydrogenated bisphenol F or polyether glycols, for example, poly(oxytetramethylene) glycol, poly(oxyethylene) glycol, poly(oxypropylene) glycol, and neopentane diol.

[0016] Another group of suitable epoxy resins include polyglycidyl ethers of polycarboxylic acids, formed by the reaction of an epoxy compound such as epichlorohydrin with an aliphatic or aromatic polycarboxylic acid such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-napthalene dicarboxylic acid, or dimerised linoleic acid. Such resins are commercially available from Hexion Inc. in their EPIKOTE and EPON lines.

[0017] Other suitable epoxy resins that can be used according to the present disclosure comprise epoxidized olefinically unsaturated alicyclic materials such as epoxy alicyclic ethers and esters, epoxy resins containing oxyalkylene groups, and epoxy novolac resins, which are prepared by reacting an epihalohydrin with the condensation product of an aldehyde with a monohydric or polyhydric phenol such as epoxy phenol novolac resins or epoxy cresol novolac resins.

[0018] Furthermore, it can be advantageous according to the present disclosure to employ a flexible polyepoxide. Exemplary of suitable materials are epoxidized soybean oil, dimer acidbased materials such as EMPOL 1010 resin, which is commercially available from BASF SE, Ludwigshafen, Germany, and rubber-modified polyepoxide resins such as the product prepared from a polyglycidyl ether of bisphenol A and an acid-functional polybutadiene.

[0019] Other suitable examples of flexible polyepoxides for use according to the present disclosure include an epoxy-functional adduct, which is prepared from a flexible acid-functional polyester and polyepoxide. The acid-functional polyester can have an acid value of at least 10 mg KOH / g, such as 140 to 350 mg KOH / or 180 to 260 mg KOH / g, as determined by ASTM 974-87.

[0020] Linear polyesters may be more suitable than branched polyesters for use herein. Acid-functional polyesters can be prepared by the polyesterification of an organic polycarboxylicacid or anhydride thereof with an organic polyol. The polycarboxylic acids and polyols can be aliphatic or aromatic dibasic acids and diols.

[0021] The diols that may be used in making the polyester include alkylene glycols, such as ethylene glycol, diethylene glycol, neopentyl glycol, and other diols such as hydrogenated bisphenol A, cyclohexanediol, cyclohexanedimethanol, caprolactonediol, for example, the reaction product of epsilon-caprolactone and ethylene glycol, hydroxy-alkylated bisphenols, polyether glycols, for example, poly(oxytetramethylene) glycol, poly(oxyethylene) glycol, poly(oxypropylene) glycol and the like. Polyols of higher functionality can also be used although diols may be more suitable. Examples include trimethylolpropane, trimethylolethane, pentaerythritol, glycerol, isosorbide, tetramethyl cyclobutane diol and the like, as well as higher molecular weight polyols such as those produced by oxyalkylating lower molecular weight polyols.

[0022] The acid component of the polyester may comprise monomeric dicarboxylic acids or anhydrides having 2 to 36 carbon atoms per molecule. Suitable acids include, for example, phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, adipic acid, azelaic acid, sebacic acid, maleic acid, glutaric acid, chlorendic acid, tetrachlorophthalic acid, tetrabromophthalic acid, decanedioic acid, dodecanedioic acid, rosin acids, diphenolic acid, gallic acid, and other dicarboxylic acids of varying types, for example, Diels- Alder adducts of unsaturated Cis fatty acids.

[0023] The polyester may include monobasic acids such as benzoic acid, stearic acid, acetic acid, hydroxystearic acid, and oleic acid. Also, there may be employed higher polycarboxylic acids such as trimellitic acid. If monobasic acids or higher polycarboxylic acids (which here means greater than two acid groups) are used, they are used in amounts less than the amount of dicarboxylic acid, such as 20 wt.% or less, or 10 wt.% or less, with weight percent based on the total weight of the acids. Where acids are referred to above, it is understood that anhydrides of those acids that form anhydrides can be used in place of the acid. Also, lower alkyl (C1-C4) esters of the acids such as dimethyl glutarate and dimethyl terephthalate can be used.

[0024] According to the present disclosure, a polyester used to make the epoxyfunctional adduct may be prepared from a polycarboxylic acid component comprising apolycarboxylic acid or mixture of acids having from 7 to 16 carbon atoms and a polyol component comprising a portion of dicthylcnc glycol.

[0025] The polyepoxides that may be used to prepare the epoxy -functional adduct of flexible acid-functional polyester and polyepoxide can be any of those as described above for the polyepoxide-functional component according to the present disclosure.

[0026] Other suitable polyepoxy-functional compounds are epoxy-functional acrylic resins. Such resins can be prepared by free-radical addition polymerization of (meth)acrylic monomers, optionally in combination with vinyl monomers or other monomers comprising at least one carbon-carbon double bond, wherein the monomer composition comprises at least one epoxy-functional compound having at least one carbon-carbon double bond.

[0027] Suitable epoxy-functional ethylenically unsaturated monomers include, for example, glycidyl (meth)acrylate, allyl glycidylether, vinyl glycidylether, vinyl cyclohexene oxide, limonene oxide, 2-ethylglycidylacrylate, 2-ethylglycidylmethacrylate, 2-(n-propyl)glycidylacrylate, 2-(n-propyl)glycidylmethacrylate, 2-(n-butyl)glycidylacrylate, 2-(n-butyl)glycidylmethacrylate, glycidylmethylmethacrylate, glycidylacrylate, (3',4'-epoxyheptyl)-2-ethylacrylate, (3',4'-epoxyheptyl)-2-ethylmethacrylate, (6',7'-epoxyheptyl)acrylate, (6', 7'-epoxyheptyl)methacrylate, allyl-3,4-epoxyheptylether, 6,7-epoxyheptylallylether, vinyl-3, 4-epoxyheptylether, 3,4-epoxyheptylvinylether, 6,7-epoxyheptylvinylether, o-vinylbenzylglycidylether, m-vinylbenzylglycidylether, p-vinylbenzylglycidylether, 3-vinyl cyclohexene oxide, alpha-methyl glycidyl methacrylate, 3,4-epoxycyclohexylmethyl (meth) acrylate and combinations thereof.

[0028] Suitable additional monomers for the preparation of the epoxy-functional acrylic resin include, for example, ethylenically unsaturated nitrile compounds; vinyl aromatic monomers; alkyl esters of ethylenically unsaturated acids; hydroxy alkyl esters of ethylenically unsaturated acids; amides of ethylenically unsaturated acids; ethylenically unsaturated acids; ethylenically unsaturated sulfonic acid monomers and / or ethylenically unsaturated phosphorous-containing acid monomers; vinyl carboxylates; conjugated dienes; monomers having at least two ethylenically unsaturated groups; and combinations thereof.

[0029] Examples of ethylenically unsaturated nitrile monomers that can be used for the preparation of the epoxy-functional acrylic resin include polymerizable unsaturated aliphatic nitrile monomers that contain from 2 to 4 carbon atoms in a linear or branched arrangement,which may be substituted either by acetyl or additional nitrile groups. Such nitrile monomers include acrylonitrile, methacrylonitrile, alpha-cyanocthyl acrylonitrile, fumaronitrile and combinations thereof, with acrylonitrile being particularly suitable.

[0030] Representative suitable vinyl-aromatic monomers include, for example, styrene, a-methylstyrene, p-methylstyrene, t-butylstyrene, and vinyltoluene.

[0031] Esters of (meth)acrylic acid that can be used for the preparation of the epoxyfunctional acrylic resin include n-alkyl esters, iso-alkyl esters or tert-alkyl esters of acrylic or (meth)acrylic acid in which the alkyl group has from 1 to 20 carbon atoms, the reaction product of methacrylic acid with glycidyl ester of a neoacid such as versatic acid, neodecanoic acid or pivalic acid and hydroxyalkyl (meth)acrylate and alkoxyalkyl (meth)acrylate monomers.

[0032] Suitable alkyl esters of (meth)acrylic acids may include, for example, C1-C20 alkyl (meth)acrylate, such as Ci-Cio-alkyl (meth)acrylates. Examples of such acrylate monomers include n-butyl acrylate, secondary butyl acrylate, methyl acrylate, ethyl acrylate, hexyl acrylate, tert-butyl acrylate, 2-ethyl-hexyl acrylate, isooctyl acrylate, 4-methyl-2-pentyl acrylate, 2-methylbutyl acrylate, methyl methacrylate, butyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, ethyl methacrylate, isopropyl methacrylate, hexyl methacrylate, cyclohexyl methacrylate and cetyl methacrylate. Esters of (meth)acrylic acids, such as methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate and combinations thereof, are particularly suitable.

[0033] The hydroxy alkyl(meth)acrylate monomers that can be used for the preparation of the epoxy-functional acrylic resin include, for example, hydroxyalkyl acrylate and methacrylate monomers based on ethylene oxide, propylene oxide and higher alkylene oxides or mixtures thereof. Examples are hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate and hydroxybutyl acrylate. Particularly suitable is 2-hydroxy ethyl (meth)acrylate.

[0034] Amides of ethylenically unsaturated acids that can be used for the preparation of the epoxy-functional acrylic resin include, for example, acrylamide, methacrylamide, and diacetone acrylamide.

[0035] Vinyl ester monomers that can be used to prepare the epoxy-functional acrylic resin include vinyl acetate, vinyl proprionate, vinyl butyrate, vinyl benzoate, vinyl-2-ethylhexanoate, vinyl stearate, and the vinyl esters of versatic acid.

[0036] The ethylenically unsaturated carboxylic acid monomers suitable for the preparation of the epoxy-functional acrylic resin include, for example, monocarboxylic acid and dicarboxylic acid monomers and monoesters of dicarboxylic acid. Particularly suitable are ethylenically unsaturated aliphatic mono- or dicarboxylic acids or anhydrides that contain from 3 to 5 carbon atoms. Examples of monocarboxylic acid monomers include acrylic acid, methacrylic acid, crotonic acid and examples of dicarboxylic acid monomers include fumaric acid, itaconic acid, maleic acid and maleic anhydride. Examples of other suitable ethylenically unsaturated acids include vinyl acetic acid, vinyl lactic acid, vinyl sulfonic acid, 2-methyl-2-propene-1- sulfonic acid, styrene sulfonic acid, acrylamidomethyl propane sulfonic acid and the salts thereof. Suitable ethylenically unsaturated carboxylic acid monomers include (meth)acrylic acid, crotonic acid, itaconic acid, maleic acid, fumaric acid and combinations thereof.

[0037] Conjugated diene monomers suitable for the preparation of the epoxy-functional acrylic resin include conjugated diene monomers, such as 1,3-butadiene, isoprene, 2,3-dimethyl- 1.3-butadiene, 2,3-dimethyl-l,2-butadiene, 2-chloro- 1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, 2,4-hexadiene, 1,3-octadiene, 2-methyl- 1,3-pentadiene, 2, 3-dimethyl- 1,3-pentadiene, 3.4-dimethyl- 1 ,3-hexadiene, 2,3-diethyl- 1 ,3-butadiene, 4,5-diethyl- 1 ,3-octadiene, 3-butyl- 1,3-octadiene, 3,7-dimethyl-l,3,6-octatriene, 2-methyl-6-methylene- 1,7 -octadiene, 7-methyl-3-methylene-l,6-octadiene, 1,3,7-octatriene, 2-ethyl- 1,3-butadiene, 2-amyl- 1,3-butadiene, 3, 7-dimethyl-l,3,7-octatriene, 3,7-dimethyl-l,3,6-octatriene, 3,7,11 -trimethyl- 1, 3, 6,10-dodecatetraene, 7,1 l-dimethyl-3-methylene-l,6,10-dodecatriene, 2,6-dimethyl-2,4,6-octatriene, 2-phenyl- 1,3-butadiene and 2-methyl-3-isopropyl- 1,3-butadiene and 1,3-cyclohexadiene and combinations thereof.

[0038] It is also possible to use a combination of two or more, such as three or more or four or more, different polyepoxy-functional compounds in the film-forming component such as any of those disclosed above.

[0039] Suitable polyepoxy-functional compounds used according to the present disclosure may include, for example, diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, resorcinol diglycidyl ether, epoxy phenol novolac resin, epoxy cresol novolac resins, epoxy functional (poly)magnesiums, epoxy functional polysulfides, epoxy-functional adducts of acid-functional polyesters and polyepoxides, for example, those that are described above.

[0040] The acrylic resins used in the present disclosure may include copolymers of one or more alkyl esters of acrylic acid or methacrylic acid, optionally together with one or more other polymerizable ethylenically unsaturated monomers. Useful alkyl esters of acrylic acid or methacrylic acid include, for example, aliphatic alkyl esters containing from 1 to 30, and such as 1 to 4 or 4 to 18 carbon atoms in the alkyl group. Examples include methyl methacrylate, ethyl methacrylate, butyl methacrylate, ethyl acrylate, butyl acrylate, and 2-ethyl hexyl acrylate.Suitable other copolymerizable ethylenically unsaturated monomers include, for example, vinyl aromatic compounds such as styrene and vinyl toluene; nitriles such as acrylonitrile and 4-methacrylonitrile; vinyl and vinylidene halides such as vinyl chloride and vinylidene fluoride and vinyl esters such as vinyl acetate.

[0041] The acrylic copolymers can include hydroxyl-functional groups, which are often incorporated into the polymer by including one or more hydroxyl-functional monomers in the reactants used to produce the copolymer. Useful hydroxyl-functional monomers include hydroxy alkyl acrylates and methacrylates, typically having 2 to 4 carbon atoms in the hydroxyalkyl group, such as hydroxyethyl acrylate, hydroxypropyl acrylate, 4-hydroxybutyl acrylate, hydroxy-functional adducts of caprolactone and hydroxyalkyl acrylates, and corresponding methacrylates, as well as the beta-hydroxy ester-functional monomers described below. The acrylic polymer can also be prepared with N-(alkoxymethyl) acrylamides and N-(alkoxymethyl) methacrylamides.

[0042] Beta-hydroxy ester-functional monomers can be prepared from ethylenically unsaturated, epoxy-functional monomers and carboxylic acids having from 5 to 20 carbon atoms, or from ethylenically unsaturated acid-functional monomers and epoxy compounds containing at least 5 carbon atoms that are not polymerizable with the ethylenically unsaturated acid functional monomer.

[0043] The film forming resin used in the present disclosure can also comprise polyurethane. Among the polyurethanes that can be used are polymeric polyols that are prepared by reacting polyester polyols or acrylic polyols, such as those mentioned above, with a polyisocyanate such that the OH / NCO equivalent ratio is greater than 1 : 1 so that free hydroxyl groups are present in the product.

[0044] According to the present disclosure, the film-forming component can include combinations of epoxy resins and acrylic resins or epoxy resins and polyurethane resins, such as those disclosed in U.S. Patent No. 5,108,832.

[0045] If the film-forming component comprises an epoxy resin and a polyamine and / or a polythiol-functional compound as a curing agent, the film- forming component may further comprise (i) a beta-hydroxy ester of (meth)acrylic acid; (ii) a (meth)acrylate-functional compound different from compound (i); or a combination thereof.

[0046] The beta-hydroxy ester of (meth)acrylic acid may comprise a plurality of betahydroxy ester of (meth)acrylic ester groups resulting from the reaction of a polyepoxide with (meth)acrylic acid. The polyepoxide can be reacted with the (meth)acrylic acid in an epoxycarboxylic acid equivalent ratio of 1:0.1 to 1:1.2, or 1:0.5 to 1:1.2, or 1:1 to 1:1.05. A particularly suitable beta-hydroxy ester of (meth)acrylic acid is the reaction product of EPIKOTE 828 (reaction product of bisphenol A with epichlorohydrin) with acrylic acid, commercially available from Allnex as EBECRYL 3720.

[0047] The polyepoxides that can be used for the reaction product of polyepoxide with (meth)acrylic acid can be those polyepoxides as disclosed above.

[0048] In addition, or alternatively to the beta-hydroxy ester of (meth)acrylic acid (i), a (meth)acrylate-functional compound (ii) different from compound (i) may be present in the filmforming component. The viscosity of the composition of the present disclosure can be adjusted thereby. Thus, it is believed that the optional component (ii) functions as a reactive diluent. The optional (meth)acrylate-functional component (ii) of the present compositions may include, for example, poly(meth)acrylates of 1,4-butanediol, neopentyl glycol, ethylene glycol, 1,2-propanediol, 1,3-propanediol, 2,2,4-trimethyl-l,3-pentanediol, 1,6-hexanediol, 1 ,4-cyclohexane dimethanol, para-xylene glycol, 1 ,4-cyclohexane diol, trimethylolethane, trimethylolpropane, pentaerythritol, polyether glycols, for example, poly(oxytetramethylene) glycol, poly(oxyethylene) glycol, poly(oxypropylene) glycol and combinations thereof.

[0049] As noted above, the film-forming component may also comprise a crosslinker. Any suitable crosslinker can be used according to the present disclosure and will be chosen by one skilled in the art to react with the functional groups of the film-forming resin. Suitable crosslinkers include, for example, polyamines, for example polyetheramines, polyamides, polyepoxides, aminoplast resins, phenolic resins, polyisocyanates, polythiols, and polyols, etc.

[0050] The curing agent may also be a latent or blocked curing agent, wherein the actual functional group that is reactive with the functional groups of the film-forming resin is generated or restored in a deblocking reaction at curing conditions, such as elevated temperatures (that is, greater than 50°C). Suitable curing agents of said type are, for example, blocked polyisocyanates. The term polyisocyanate as used herein encompasses blocked and free polyisocyanates. Latent or blocked curing agents are particularly suitable to provide single component compositions, which may offer greater storage stability and pot life prior to application and curing.

[0051] The polyamine curing agent can include, for example, aliphatic polyamines, aromatic polyamines, polyamine amides, polyetheramines, for example those commercially available from Huntsman Cooperation, The Woodlands, Texas, polysiloxane amines, polysulfide amines or combinations thereof. Examples include diethylene triamine, 3,3-amino-bis-propylamine, triethylene tetraamine, tetraethylene pentamine, m-xylylenediamine, isophorone diamine, l,3-bis(aminoethyl)cyclohexane, bis(4-aminocyclohexyl)methane, N-aminoethyl piperazine, 4,4’ -diaminodiphenyl methane, 4,4’-diamino-3,3’-diethyl diphenyl methane and diamino diphenylsulphone and the reaction product of a polyamine and an aliphatic fatty acid such as the series of materials sold by BASF under the trademark VERSAMID, which are particularly suitable.

[0052] In addition, adducts of any above polyamines can also be used. The adduct of polyamine is formed by reacting polyamine with a suitable reactive compound, such as an epoxy resin. This reaction will decrease the content of free amine in the curing agent, making it more useful at low temperature and / or high humidity environment.

[0053] As a curing agent, various poly etheramines, such as various JEFFAMINES available from Huntsman Corp., including, but not limited to, JEFF AMINE D-230, JEFF AMINE D-400, JEFFAMINE 600, JEFF AMINE 1000, JEFF AMINE 2005 and JEFF AMINE 2070, etc., can also be used.

[0054] Various polyamides can also be used. Generally, polyamides contain reaction products of dimer fatty acid and polyethyleneamine, and small amounts of monomer fatty acid. Dimer fatty acid is prepared by the oligomerization of monomer fatty acid. Polyethyleneamine can include diethylenetriamine, triethylenetetraamine, tetraethylenepentaamine, etc., wherein the most commonly used is diethylenetriamine. When polyamides are used as the curing agent, itmay impart one or more desirable properties to the coating, such as corrosion resistance, water resistance, and / or good flexibility.

[0055] The polythiol compounds useful as curing agents may include polysulfide thiols, polyether thiols, polyester thiols, pentaerythritol based thiols, or combinations thereof. A particularly suitable polythiol compound is THIOPLAST G4, commercially available from Nouryon.

[0056] As mentioned above, if the film-forming resin comprises an epoxy resin, a polyamine, a polythiol compound, or a combination thereof may be used as a crosslinker.

[0057] In the coating composition of the present disclosure, the equivalent ratio of the combined functional groups in the film-forming resin, such as epoxy groups if an epoxy resin is used, to the functional groups / active hydrogen in the curing agent may be from 2:1 to 1:2, such as from 1.05 : 1.0 to 1 :2, or from 1 : 1.4 to 1:2.

[0058] The coating composition may comprise the film-forming component in any suitable amount. For example, the coating composition may contain 10 wt.% or greater of the film- forming component, such as 20 wt.% or greater or 30 wt.% or greater. The coating composition may, for example, contain 60 wt.% or less of the film-forming component, such as 50 wt.% or less, 40 wt.% or less or 20 wt.% or less. The coating composition can, for example, comprise the film- forming component in an amount in a range of any of the above-mentioned values such as from 10 wt.% to 60 wt.%, from 10 wt.% to 50 wt.% or from 20 wt.% to 40 wt.%. Wt.% as reported herein is based on total solid weight of the composition unless indicated otherwise.

[0059] The present coating compositions further comprise a silicon component. The silicon component may comprise a silicone resin, such as a siloxane resin. A silicone resin will be understood as a resin comprising one or more Si molecules, such as one or more siloxane groups (Si-O-Si). Suitable silicone and siloxane resins are commercially available from Wacker, such as in their SILRES, GENIOSIL, and SEMICOSIL lines. When the silicon component comprises a silicone resin, the resin may be part of the film-forming component; that is, the silicone resin may react with itself, the film-forming resin and / or the curing agent. The silicon component may be present in an amount of 10 wt.% or greater, such as 15 wt.% or greater or 20 wt.% or greater, or 40 wt.% or less, such as 30 wt.% or less, 25 wt.% or less, or in a range of 10 to 40 wt.%, 20 to 30 wt.% or 15 to 25 wt.%. The amount of silicon component is reported hereinseparately from the amount of film-forming component, even though some or all of the silicone component may react with compounds in the film-forming component and form part of the film.

[0060] The coating compositions of the present disclosure comprise a phyllosilicate component, such as a plate-like phyllosilicate. The phyllosilicate component is different from the silicon component. As used herein, the term “phyllosilicate” refers to a group of minerals having sheets or layers of silicates having a basic structure based on interconnected six membered rings of SiOT4tetrahedra that extend outward in infinite sheets where 3 out of the 4 oxygens from each tetrahedra are shared with other tetrahedra resulting in phyllosilicates having the basic structural unit of Si20s'2. Phyllosilicates may comprise hydroxide ions located at the center of the tetrahedra and / or cations such as, for example, Fe+2, Mg+2, or Al+3, that form cation layers between the silicate sheets where the cations may coordinate with the oxygen of the silicate layer and / or the hydroxide ions. Examples of phyllosilicates pigments include mica, chlorites, vermiculite, serpentine, talc, and the clay minerals. The sheet-like structure of the phyllosilicate pigment may result in particles having a plate-like structure, and such plate-like phyllosilicate may be used according to the present disclosure. The clay minerals include, for example, kaolin clay, kaolinite, and smectite clay.

[0061] The phyllosilicate may have an average equivalent spherical diameter of at least 50 nm and up to 25 microns or higher as determined using dynamic light scattering, such as with a SEDIGRAPH III PLUS particle size analyzer, available from Micromeritics Instrument Corp. The phyllosilicate often has substantially opposing surfaces and particles typically exhibit an aspect ratio of the longest axis to the shortest axis of, for example, at least 2:1. For example, the phyllosilicate may have an average equivalent spherical diameter of at least 50 nm, such as at least 0.2 microns, such as at least 0.4 microns, such as at least 0.6 microns, such as at least 1 micron, such as at least 2 microns, such as at least 3 microns, such as at least 4 microns, such as at least 5 microns. The phyllosilicate may have an average equivalent spherical diameter of no more than 25 microns, such as no more than 15 microns, such as no more than 10 microns, such as no more than 5 microns, such as no more than 3.5 microns, such as no more than 2.5 microns, such as no more than 1.9 microns, such as no more than 1.5 microns, such as no more than 1 micron.

[0062] The phyllosilicate may be present in an amount of 5 wt.% or greater, such as 10 wt.% or greater or 15 wt.% or greater, or 50 wt.% or lower, such as 30 wt.% or lower or 25 wt.%or lower, such as 10 to 50 wt.%, 10 to 30 wt.% or 15 to 25 wt.%. It will be appreciated that phyllosilicates arc often found in rheology modifiers. In such applications, the phyllosilicates are often ground or pulverized, and have a thixotropic effect on the composition. Moreover, they are typically used in amounts of less than 3 wt.%, such as 1 wt.% or less. In contrast, the phyllosilicate used in the phyllosilicate component in these amounts would not have an appreciable effect on the composition. By “appreciable effect” is meant that one skilled in the art would not see more than an insignificant thixoptropic effect, if at all, in the viscosity of the composition. Stated another way, one would not use the phyllosilicate component materials of the present disclosure in amounts less than 3 wt.% to adjust the viscosity to the desired level. Whether a phyllosilicate has a thixotropic effect on a composition at less than 3 wt.% can be determined using a viscometer using any standard method. Accordingly, if rheology modifiers comprising phyllosilicates are used in the present coatings, they are not considered in the wt.% of the phyllosilicates.

[0063] The present compositions may further comprise a silica component. The silica component can take many different forms, such as particulate silica and / or silicate, or a dispersion or solution thereof; a particularly suitable silica component comprises basalt. If particulate, they can be any shape or size. Suitable particulate silica is widely commercially available, such as from Sibelco or Wacker. Mixtures of one or more different kinds, sizes, shapes and the like of silica may be used. It will be appreciated that phyllosilicates are within the general definition of “silica component” and are distinguished from the silica component for purposes of the present disclosure as being layered materials. Thus, if a silica component is present, it is also different from the phyllosilicate component. As used herein, a component is “different from” another component if the component comprises different materials.

[0064] The coating composition may contain 3 wt.% or greater of the silica component, such as 4 wt.% or greater, 5 wt.% or greater or 10 wt.% or greater, or 50 wt.% or less of the silica component, such as 40 wt.% or less, 30 wt.% or less, or 15 wt.% or less, or 3 to 50 wt.%, from 4 to 40 wt.% or from 4 to 15 wt.%. For clarity, the phyllosilicate is not considered when calculating the wt.% of the silica component.

[0065] The coating compositions of the present disclosure may further comprise TiCh, such as in an amount of 3 wt.% or greater, such as 5 wt.% or greater or 10 wt.% or greater and may be present in any amount of 25 wt.% or less, such as 20 wt.% or less, or 15 wt.% or less, orin a range of 5-20 wt.% or 10-15 wt.%. Alternatively, it may be desirable to formulate the present coating compositions as being substantially free, essentially free, or completely free (as described below) of TiCh. The minimization, if not elimination, of TiCh allows for coating compositions to be formulated to result in a transparent or semi-transparent coating layer.Transparent in this context means one can see through the coating layer, and semi-transparent means the coating layer allows energy to pass through so that electromagnetic energy (e.g., visible light) can pass, but objects on the opposite side of the viewer are not clearly visible. The coating compositions can also be formulated with pigments or other colorants to impart a desired color to the coating compositions and coating layers deposited therefrom, other than the white, grey and / or black colors that result from the components themselves.

[0066] The coating compositions of the present disclosure may further comprise one or more additional additives, including a phosphate source, a borate source, a zinc source, an acid source and / or reinforcing filler. The phosphate source can comprise a variety of materials, such as, for example, phosphoric acid, mono- and diammonium phosphate, triphenyl phosphate, tris-(2-chloroethyl)phosphate, tri(2-chloroisopropyl)phosphate, phosphorus-containing amides such as phosphorylamide, and melamine pyrophosphate. Suitably, the source of phosphorous is an ammonium polyphosphate represented by the formula (NH4)n+2 PnOin+i , wherein n is an integer of at least 2; n can be an integer of at least 50. The composition of the present disclosure may contain the phosphate source in an amount of 3 wt.% or greater, such as 5 wt.% or greater, 10 wt.% or greater, 15 wt.% or greater, 20 wt.% or greater, or 25 wt.% or greater. The coating composition may comprise the phosphate source in an amount of 50 wt.% or less, such as 45 wt.% or less, or 40 wt.% or less, or 35 wt.% or less, or 20 wt.% or less, or 15 wt.% or less. The coating composition may comprise the phosphate source, if used, in a range of any of the above values such as from 3 to 50 wt.%, from 5 to 20 wt.%, from 5 to 15 wt.%, or from 10 to 50 wt.%.

[0067] Borate source” as used herein means any boron-containing material that contains boric acid, or condensation or dehydration products (including oxides) thereof, or salts or esters of any of the foregoing. Suitable borate sources include, for example, ammonium pentaborate, boric acid, metal borates such as zinc borate, boron oxide, borates such as sodium borate, potassium borate, and ammonium borate, borate esters such as butyl borates or phenyl borates, and combinations thereof.

[0068] The borate source, if used, may be used in an amount of 5 wt.% or greater, such as 6 wt.% or greater, such as 7 wt.% or greater, such as 8 wt.% or greater, such as 9 wt.% or greater, such as 10 wt.% or greater. The coating composition may comprise the borate source in an amount of 40 wt.% or less, such as 35 wt.% or less, 30 wt.% or less, or 20 wt.% or less. The coating composition may comprise the borate source in a range of any of the above values such as from 5wt.% to 40 wt.%, or from 6 wt.% to 20 wt.%, or from 9 wt.% to 20 wt.%.

[0069] The optional source of zinc (“zinc source”) can comprise a variety of materials. Examples of suitable materials that are sources of zinc include zinc oxide, zinc salts, such as zinc borate. It is believed that the zinc material may contribute to the formation of a small-celled (such as 50 microns or below) structure in the char. The small cells of the chai’ may provide better insulation of the substrate and are better able to retain the char's integrity and adhere to the substrate as compared to larger cells of char. Thus, cracking of the char and its breaking away from the substrate are minimized and a greater measure of protection is afforded to the underlying substrate. Examples of suitable materials that are sources of zinc include zinc oxide, zinc salts, such as zinc borate and zinc phosphate, zinc carbonate, zinc metal, and combinations thereof. The zinc source, if used, may be used in an amount of 5 wt.% or greater, such as 10 wt.% or greater, or in an amount of 40 wt.% or less, such as 30 wt.% or less or in a range of any of the above values such as from 5 wt.% to 40 wt.%, or from 10 wt.% to 30 wt.%.

[0070] The acid source may comprise ammonium phosphate, ammonium polyphosphate, diammonium diphosphate, diammonium pentaborate, which are phosphoric acid-generating materials, boric acid, metal or organic borates and combinations thereof. The acid source, if used, may be used in an amount of 5 wt.% or greater, such as 10 wt.% or greater or in an amount of 60 wt.% or less, such as 50 wt.% or less, or 40 wt.% or less, or in a range of any of the above values such as from 5 wt.% to 60 wt.%, or from 10 wt.% to 50 wt.%.

[0071] It will be appreciated that many of the components of the present composition may serve more than one function in the composition. That is, a single material may be a source of more than one of the recited components of the composition. For example, zinc borate can provide a source of zinc and a source of borate; zinc phosphate may provide a source of zinc and a source of phosphate, and the like. If a material is a source of more than one component, its weight is used in the wt.% calculation of each component. That is, the amount of zinc in zinc phosphate is included in the total amount of zinc and the amount of phosphate in the totalamount of phosphate. Many sources of acid also contribute other components and their weight would be counted in both the amount of acid and the amount of the other component.

[0072] The optional reinforcing fillers may be chosen from among a large array of conventionally utilized materials, including fibrous reinforcements. Examples of fibrous reinforcements include glass fibers, ceramic fibers, e.g., aluminum oxide / silicon oxide, graphite fibers, mineral fibers and basalt fibers, which can be used in an amount of 10 wt.% or less, such as 5 wt.% or less, such as 4 wt.% or less, or 2 wt.% or less, or in an amount of 0.1 wt.% or greater, such as 0.2 wt.% or greater, 0.5 wt.% or greater, or 1 wt.% or greater, or in a range of any of the above-mentioned values such as from 0.1 wt.% to 5 wt.% or from 1 wt.% to 4 wt.%. It will be appreciated that many of the phyllosilicates used according to the present disclosure may also provide reinforcement or strengthening of the coating compositions and so the “optional reinforcing fillers” refers to those used in addition to the phyllosilicates.

[0073] The compositions of the present disclosure may also contain a variety of conventional additives, such as rheology additives, organic solvents, foam stabilizers, pigments, and the like. These ingredients are optional and can be added in varying amounts. Typically, if additional additives are used, they are present in a total amount of 1 wt.% or greater, such as 2 wt.% or greater, or 5 wt.% or greater, or 10 wt.% or greater. The additional additives, if used, can for example be present in the compositions according to the present disclosure in an amount of 20 wt.% or less, such as 15 wt.% or less, or 12 wt.% or less. The composition may comprise the optional additional additives in a range of any of the above values such as from 1 to 20 wt.%, 2 to 20 wt.% or 5 to 15 wt.%.

[0074] It might also be desirable that the coating compositions of the present disclosure specifically exclude certain chemicals or components. For example, the present compositions may be substantially free, essentially free, or completely free of one or more of the following: a borate source, alkyl phosphorus acid(s), melamine, ethylenically unsaturated monomer residues such as those from (meth)acrylic acid and / or styrene, a surfactant including, but not limited to, a non-ionic surfactant, silicates (other than phyllosilicates) including, but not limited to, layered silicate and aluminum silicate(s), and piperazine salt(s), any of the above reinforcing fillers, TiCh and solvent. “Substantially free” as used in the context of a composition being free from a material means the composition comprises less than 1 wt.% of any of these compounds, “essentially free” means 0.5 wt.% or less of any of the compounds, and “completely free” meansthat the compounds contain, if any, only trace amounts such as would be present as an impurity in another compound. It will be appreciated that melamine and melamine derivatives arc a specific example of a gas source, discussed below, but, because they may be a material of concern, when the present compositions are substantially free, essentially free, or completely free melamine and / or melamine derivatives, this means the composition comprises less than 1 wt.% of any of these compounds, “essentially free” means 0.5 wt.% or less of any of the compounds, and “completely free” means that the compounds contain, if any, only trace amounts such as would be present as an impurity introduced through another compound. “Melamine derivatives” as used herein means components that contain a melamine moiety that will decompose at elevated temperature (above 200°C) to form an inert gas. “Melamine” is used herein to refer collectively to melamine and melamine derivatives.

[0075] The coating compositions of the present disclosure may also be free of a gas source. A “gas source” refers to a compound providing an expansion gas upon thermal decomposition. The expansion gas serves to cause the composition to foam and swell when exposed to high temperature or flames. Because it may be desired to minimize the expansion of a coating upon heating, gas generating compounds may be excluded from the present compositions. It will be appreciated that very minor amounts of these materials may be present and result in some expansion upon heating, but that is not an intended result of the present coatings; that is, these materials are not added for the purpose of promoting intumescence. A coating composition is “substantially free of a gas source” if it has less than 8 wt.% of a gas source, “essentially free of a gas source” if it has less than 5 wt.% of a gas source, and “completely free of a gas source” if it has less than 2 wt.% of a gas source.

[0076] The present compositions may be either one component (“IK”), or multicomponent compositions such as two component (“2K”) or more. A IK composition will be understood as referring to a composition wherein all the coating components are maintained in the same container after manufacture, during storage, etc. A IK composition can be applied to a substrate and cured by any conventional means, such as by heating, forced air, and the like. The present compositions can also be multi-component, which will be understood as compositions in which various components are maintained separately until just prior to application. The present compositions can be thermoplastic or thermosetting. For example, the present compositions might be packaged as a 2K system, with the film-forming resin in a first package (A) and acuring agent therefor in a second package (B), whereby all of the other components used in the coating composition arc used in any combination in either package (A) or package (B) or in both, or some or all may be in one or more further packages (C). The individual packages are mixed prior to use of the composition.

[0077] The coating composition of the present disclosure may be in the form of a thick material such as a mastic, with “thick” referring to a material having a viscosity above 10 Pas when measured at ambient temperature and 0.1 s"1shear rate. It is particularly suitable that the composition be solvent-free and spray-applied. If desired, thinning can be accomplished with a variety of conventional solvents such as, xylene, methylene chloride, or 1,1,1 -trichloroethane. Other methods of application could be used, such as dipping, rolling, brushing and / or application robotically; application can be by precision spraying, in which the composition is sprayed to a specific portion of the substrate without overspray.

[0078] The coating composition of the present disclosure may be applied to provide the dry film thicknesses (“DFT”) as desired. Suitable dry film thicknesses can range from 10 -20,000 microns, such as 50 - 5000 microns, such as 100 - 2000 microns. The desired DFT can vary depending on the application. For use on energy storage devices, such as lithium batteries, a DFT ranging from 200 to 5000 microns, such as 200 to 3000, such as 1000 + / - 100, may be suitable. It will be appreciated that there is often limited space within a battery pack, and so a smaller DFT might be particularly suitable. It is for this reason that non-intumescent coatings are also desired.

[0079] Alternatively, the compositions of the present disclosure can be formed into a self-supported film and / or sheet. This can be done using any technique known to a person skilled in the art, for example a cast-molding process, by impregnating a mesh with the coating composition, and the like. The film and / or sheet can be cured to form a crosslinked selfsupported film and / or sheet that can then be applied to a substrate. It is also within the present disclosure that after the forming step the uncured or partially cured film and / or sheet is applied to a substrate and then subsequently cured to obtain the coating layer according to the present disclosure. The film and / or sheet may be applied to the substrate through an adhesive.Accordingly, when reference is made herein to a substrate being “coated with”, having “applied” thereto, or like terms, the present composition(s), this includes coating by application of a film and / or sheet formed from the composition(s).

[0080] The present coatings and self-supporting sheets and / or films can be applied to any substrates known in the art, for example, automotive substrates, marine substrates, industrial substrates, heavy-duty equipment, packaging substrates, lumber, wood flooring and furniture, apparel, electronics including housings and circuit boards and including consumer electronics such as housings for computers, notebooks, smartphones, tablets, televisions, gaming equipment, computer equipment, computer accessories, MP3 players, glass and transparencies, sports equipment and the like. These substrates can be, for example, metallic or non-metallic. Metallic substrates include metal sheet, tin, steel, tin-plated steel, chromium passivated steel, galvanized steel, aluminum, and aluminum foil. Metal sheet as used herein refers to flat metal sheet and coiled metal sheet, which is coiled, uncoiled for coating, and then re-coiled for shipment to a manufacturer. Non-metallic substrates include polymeric, plastic, polyester, polyolefin, polyamide, cellulosic, polystyrene, polyacrylic, poly(ethylene naphthalate), polypropylene, polyethylene, nylon, EVOH, polylactic acid, other “green” polymeric substrates, poly(ethyleneterephthalate) (“PET”) including post-consumer or recycled PET (“rPET”), polycarbonate, polycarbonate acrylobutadiene styrene (“PC / ABS”), SMC, carbon fiber, polyamide, wood, veneer, wood composite, particle board, medium density fiberboard, cement, stone, glass, paper, cardboard, textiles, leather - both synthetic and natural, and the like. The substrate may also be 3D printed.

[0081] The substrate can be one that has been already treated in some manner, such as to impart visual and / or color effect. For instance, 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, cladded, or any combination thereof prior to application of the coating composition. The substrate can be treated using any of the previously described methods prior to application of the coating composition such as by dipping the substrate in a cleaner and / or deoxidizer bath prior to applying the coating composition. The substrate can also be plated prior to applying the coating composition. As used herein, “plating” refers to depositing a metal over a surface of the substrate.

[0082] The present disclosure is further directed to a method for using the coating composition / film / sheet of the present disclosure to coat at least a portion of a surface of a substrate, to a substrate comprising a surface coated at least in part with any of the coatingcomposition / film / sheet of the present disclosure, and to a method for coating a substrate comprising applying a coating layer from any of the coating compositions / films / shccts of the present disclosure and one or more additional coating layers, which together form a coating stack. “Applying,” “applied to,” “application” and any variants thereof, when referring to the coating composition, means coating with and, when referring to the film and / or sheet, means that the film / sheet can be affixed or attached to the substrate, such as by use of an adhesive, and / or positioned adjacent to the substrate. “Applying” therefore includes placing a self-supported film and / or sheet adjacent to a surface of an article.

[0083] Articles comprising the coated substrate are also within the present disclosure. The article can be a structure. Particularly suitable articles are structures and vehicles.“Structure” as used herein refers to any part of a building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structures, wind turbines, walls, piers, docks, levees, dams, shipping containers, trailers, and any metal structure that is exposed to a corrosive environment. “Structure” is also used herein collectively to refer to a structure or any part(s) thereof. “Vehicle” as used herein refers to in its broadest sense all types of vehicles, including conventional, electrical and hybrid vehicles, such as car’s, trucks, buses, tractors, harvesters, heavy duty equipment, vans, golf carls, motorcycles, bicycles, e-bikes, railcars, subway cars, airplanes, helicopters, boats of all sizes and the like. “Vehicle” is also used herein collectively to refer to a vehicle or any part(s) thereof.

[0084] Another particularly suitable article can be an energy storage device, such as a battery, such as a lithium ion battery, or battery component. The battery may be, for example, an electric vehicle battery, and the battery component may be an electric vehicle battery component. A “battery component” may be any component found in a battery, such as a lithium-ion battery. The battery component may comprise, for example, an electrode, a battery cell, a battery shell, a battery module, a battery pack, a battery box, a battery cell casing, a pack shell, a battery lid and tray, a thermal management system, a battery housing, a module housing, a module racking, a battery side plate, a battery cell enclosure, a cooling module, a cooling tube, a cooling fin, a cooling plate, a bus bar, a battery frame, an electrical connection, metal wires, or copper or aluminum conductors or cables. Other energy storage devices include, but are not limited to, fuel cells and hydrogen tanks. “Battery” is used herein collectively to refer to a battery or any battery component(s).

[0085] The coating composition, film and / or sheet can be applied to any structural element of a battery to obtain a battery according to the present disclosure. The battery may comprise exterior wall elements defining a housing and optionally interior wall elements, wherein the coating or self-supported film or sheet is at least partially applied to the external and / or internal side of any of the exterior wall elements and / or to any side of any of the interior wall elements, if present. The exterior wall and / or interior wall elements may comprise composite, steel, aluminum and / or polycarbonate. The present coatings may be particularly suitable for use on the inside of a battery or other energy storage device, where space for a coating layer or film may be limited. This can prevent or at least minimize the likelihood of overheating of the substrate during a thermal runaway event.

[0086] The battery, particularly a lithium-ion battery, may include a battery pack comprising a plurality of individual battery cells, wherein the present coating composition, film and / or sheet is positioned to thermally insulate at least some of the individual battery cells from each other in the expanded and optionally charred state, such as in between two battery cells. In addition, the coating composition, film and / or sheet may be applied to or placed adjacent to the housing walls and interior dividing walls of the battery pack as discussed above.

[0087] It might be desirable to use one or more additional fire-retardant materials and / or fire mitigation means within and / or around the battery. For example, a thermally insulating material or a high strength material could be wrapped around or otherwise positioned between battery cells, or around the perimeter or interior of the battery housing. Examples of such material include fiberglass, mineral wool, silica / silica fibers, alumina, Kevlar, Nomex, calciumsilicate, or calcium silicate fibers; these materials can be, for example, in a sheet or other selfsupported form. Foams could also be used, such as polyurethane / polyurea foam with fire retardants. Physical barriers could also be employed, such as cooling fins interposed between battery cells, mica boards, Aerogel blankets, and / or mineral / glass / carbon fiber-containing blankets.

[0088] To provide fire protection for articles comprising a battery and their users, the present disclosure is also directed to a method for providing such protection comprising applying the coating composition, film and / or sheet to at least a portion of the surface of the article adjacent to the battery, such as between the battery and the surface to insulate the article surface from the battery. In such cases a conventional battery or a battery according to the presentdisclosure can be employed. The article may be, for example, a mobile phone, a tablet, or a laptop computer.

[0089] As noted above, the article may be a vehicle such as a hybrid or electric car, bus or truck. In such vehicles it is common to position the battery, due to its weight, as a flat battery pack underneath the floor portion of the vehicle body, such as the car body. The coating composition, film and / or sheet of the present disclosure may be applied to the floor portion of the vehicle adjacent to the battery, such as between the battery and the vehicle body. In an event of a thermal runaway of the battery or a battery fire, the car body, especially the passenger cabin, would be protected by the coating layer / film / sheet of the present disclosure so that the battery box will resist flame, and any fire inside the battery box will not spread into the passenger cabin; heat-up of the passenger cabin may also be limited for a prolonged period of time so that the passengers can safely escape from the vehicle in case of such an incident.

[0090] It may also be desirable to apply to a vehicle comprising an electric battery, particularly the area in contact with or adjacent the battery, a fire-resistant ecoat coating layer. “Fire-resistant ecoat” and like terms as used herein refer to an ecoat layer that has been deposited from an electrodepositable composition comprising a fire-retardant pigment, an inorganic, pigment, such as a phyllosilicate pigment, as described above, and / or having a pigment-to-binder (P:B) ratio of 0.4:1 or higher, such as 0.5:1 to 2.0:1. These coatings, due to their use of a fire-retardant pigment or high pigment content, may be less likely to be combustible as compared to electrodepositable coatings having a lower pigment content. Suitable examples of fire-resistant ecoat include those disclosed in U.S. Patent No. 10,697,081; U.S. Pub. No. 2023 / 044601 Al, IntT Pub. No. 2021 / 127327A1; and IntT Pub. No. 2022 / 133202 Al. Fire-retardant adhesives, sealants, gap fillers, pottants, and encapsulants can also be used, such as those formed from a composition comprising a fire-retardant. Fire retardants may be available as a powder that may be mixed with a composition, a foam, or a gel that may form a coating that may impart fireretardants to a substrate surface. Suitable examples include those disclosed above as well as those disclosed in IntT Publ. No. 2021 / 211722A1, pars. 57-309; IntT Publ. No. 2021 / 211183A1, pars. 44-178; IntT Publ. No. 2021 / 211184A1, pars. 52-252; IntT Publ. No. 2021 / 211694A1, pars. 60-299; PCT Appn. No. PCT / US2023 / 067964, pars. 44-183; U.S. Provisional Appn. No.63 / 505,645, pars. 51-252; U.S. Provisional Appn. No. 63 / 497,303, pars. 31-141; and U.S.Provisional Appn. No. 63 / 477,568, pars. 58-223.

[0091] Any numerical range recited herein is intended to include all sub-ranges subsumed therein. Singular’ encompasses plural and vice versa. For example, although reference is made herein to “a” film-forming component, “a” film-forming resin, “a” curing agent, “a” silicone component, “a” phyllosilicate, and the like, one or more of each of these and any other components can be used. Also, as used herein, the term “polymer” refers to prepolymers, oligomers and both homopolymers and copolymers; the prefix “poly” refers to two or more. Amine includes polyamine. When ranges are given, any endpoints of those ranges and / or numbers within those ranges can be combined with the scope of the present disclosure.“Including”, “such as”, “for example” and like terms means “including / such as / for example but not limited to”. The terms “acrylic” and “acrylate” are used interchangeably (unless to do so would alter the intended meaning) and include acrylic acids, anhydrides, and derivatives thereof, lower alkyl-substituted acrylic acids, e.g., C1-C2 substituted acrylic acids, such as methacrylic acid, methacrylic acid, etc., and their Ci-Ce alkyl esters and hydroxyalkyl esters, unless clearly indicated otherwise.Aspects:

[0092] Aspect 1. A coating composition, comprising:a. a film forming component;b. a silicon component; andc. a phyllosilicate component,wherein the silicon component and phyllosilicate component are different and wherein a coating layer deposited from the composition, when cured to a dry film thickness of 2 mm + / -0.5 mm, has anti-blast properties.

[0093] Aspect 2. A coating composition, comprising:a. a film forming component;b. a silicon component; andc. a phyllosilicate component,wherein the silicon component and phyllosilicate component are different.

[0094] Aspect 3. The coating composition of any preceding aspect, wherein the coating composition is substantially free, essentially free and / or completely free of a gas source.

[0095] Aspect 4. The coating composition of any preceding aspect, wherein the film-forming component comprises a self-crosslinking resin.

[0096] Aspect 5. The coating composition of any preceding aspect, wherein the film-forming component comprises a film-forming resin and a curing agent.

[0097] Aspect 6. The coating composition of aspect 5, wherein the film-forming resin comprises an epoxy resin and the curing agent comprises polyamine.

[0098] Aspect 7. The coating composition of any of aspects 5-6, wherein the equivalent ratio of combined functional groups in the film-forming resin to the functional groups in the curing agent is from 2:1 to 1:2.

[0099] Aspect 8. The coating composition of aspect 7, wherein the ratio is from 1.05:1.0 to 1:2.

[0100] Aspect 9. The coating composition of aspect 7, wherein the ratio is from 1:1.4 to 1:2.

[0101] Aspect 10. The coating composition of any preceding aspect, wherein the film-forming component comprises 5 wt.% or greater of the total weight of the composition.

[0102] Aspect 11. The coating composition of any preceding aspect, wherein the film-forming component comprises 10 wt.% or greater of the total weight of the composition

[0103] Aspect 12. The coating composition of any preceding aspect, wherein the film-forming component comprises 15 wt.% or greater of the total weight of the composition

[0104] Aspect 13. The coating composition of any preceding aspect, wherein the film-forming component comprises 50 wt.% or lower of the total weight of the composition.

[0105] Aspect 14. The coating composition of any preceding aspect, wherein the film-forming component comprises 40 wt.% or lower of the total weight of the composition.

[0106] Aspect 15. The coating composition of any preceding aspect, wherein the film-forming component comprises 30 wt.% or lower of the total weight of the composition.

[0107] Aspect 16. The coating composition of any preceding aspect, wherein the film-forming component comprises 5 to 50 wt.% of the total weight of the composition.

[0108] Aspect 17. The coating composition of any preceding aspect, wherein the film-forming component comprises 10 to 20 wt.% of the total weight of the composition.

[0109] Aspect 18. The coating composition of any preceding aspect, wherein the film-forming component comprises 13 to 18 wt.% of the total weight of the composition.

[0110] Aspect 19. The coating composition of any preceding aspect, wherein the composition further comprises a silica component that is different from the silicon component and the phyllosilicate component.

[0111] Aspect 20. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising particulate silica.

[0112] Aspect 21. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising silicate.

[0113] Aspect 22. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 3 wt.% or greater of the total weight of the composition.

[0114] Aspect 23. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 5 wt.% or greater of the total weight of the composition.

[0115] Aspect 24. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 10 wt.% or greater of the total weight of the composition.

[0116] Aspect 25. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 50 wt.% or lower of the total weight of the composition.

[0117] Aspect 26. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 40 wt.% or lower of the total weight of the composition.

[0118] Aspect 27. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 30 wt.% or lower of the total weight of the composition.

[0119] Aspect 28. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 3 to 50 wt.% of the total weight of the composition.

[0120] Aspect 29. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising 4 to 40 wt.% or 4 to 15 wt.% of the total weight of the composition.

[0121] Aspect 30. The coating composition of any preceding aspect, wherein the composition further comprises a silica component comprises basalt.

[0122] Aspect 31. The coating composition of any preceding aspect, wherein the silicon component comprises silicone resin.

[0123] Aspect 32. The coating composition of aspect 31, wherein the silicone resin comprises siloxane resin.

[0124] Aspect 33. The coating composition of any preceding aspect, wherein the silicon component comprises 10 wt.% or greater of the total weight of the composition.

[0125] Aspect 34. The coating composition of any preceding aspect, wherein the silicon component comprises 15 wt.% or greater of the total weight of the composition.

[0126] Aspect 35. The coating composition of any preceding aspect, wherein the silicon component comprises 20 wt.% or greater of the total weight of the composition.

[0127] Aspect 36. The coating composition of any preceding aspect, wherein the silicon component comprises 40 wt.% or lower of the total weight of the composition.

[0128] Aspect 37. The coating composition of any preceding aspect, wherein the silicon component comprises 30 wt.% or lower of the total weight of the composition.

[0129] Aspect 38. The coating composition of any preceding aspect, wherein the silicon component comprises 10 to 40 wt.% of the total weight of the composition.

[0130] Aspect 39. The coating composition of any preceding aspect, wherein the silicon component comprises 20 to 30 wt.% of the total weight of the composition.

[0131] Aspect 40. The coating composition of any preceding aspect, wherein the silicon component comprises 15 to 25 wt.% of the total weight of the composition.

[0132] Aspect 41. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises clay.

[0133] Aspect 42. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises kaolin.

[0134] Aspect 43. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises kaolinite.

[0135] Aspect 44. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 5 wt.% or greater of the total weight of the composition.

[0136] Aspect 45. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 10 wt.% or greater of the total weight of the composition

[0137] Aspect 46. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 15 wt.% or greater of the total weight of the composition

[0138] Aspect 47. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 50 wt.% or lower of the total weight of the composition.

[0139] Aspect 48. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 40 wt.% or lower of the total weight of the composition.

[0140] Aspect 49. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 30 wt.% or lower of the total weight of the composition.

[0141] Aspect 50. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 10 to 50 wt.% of the total weight of the composition.

[0142] Aspect 51. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 10 to 30 wt.% of the total weight of the composition.

[0143] Aspect 52. The coating composition of any preceding aspect, wherein the phyllosilicate component comprises 15 to 25 wt.% of the total weight of the composition.

[0144] Aspect 53. The coating composition of any preceding aspect, wherein the composition further comprises a colorant.

[0145] Aspect 54. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of TiCh.

[0146] Aspect 55. The coating composition of any preceding aspect, wherein the composition further comprises a phosphate source.

[0147] Aspect 56. The coating composition of any preceding aspect, wherein the composition further comprises a borate source.

[0148] Aspect 57. The coating composition of any preceding aspect, wherein the composition further comprises a zinc source.

[0149] Aspect 58. The coating composition of any preceding aspect, wherein the composition further comprises an acid source.

[0150] Aspect 59. The coating composition of any preceding aspect, wherein the composition further comprises a reinforcing filler.

[0151] Aspect 60. The coating composition of any of aspects 1-55 or 57-59, wherein the composition is substantially free, essentially free, or completely free of a borate source.

[0152] Aspect 61. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of alkyl phosphorous acid(s).

[0153] Aspect 62. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of ethylenically unsaturated monomers or residues thereof.

[0154] Aspect 63. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of surfactant.

[0155] Aspect 64. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of piperazine.

[0156] Aspect 65. The coating composition of any of aspects 1-58 or 60-64, wherein the composition is substantially free, essentially free, or completely free of reinforcing fillers.

[0157] Aspect 66. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of solvent.

[0158] Aspect 67. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of a gas source.

[0159] Aspect 68. The coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, or completely free of melamine.

[0160] Aspect 69. The coating composition of any preceding aspect, wherein the film-forming component comprises a film-forming resin and a curing agent, each of which is packaged in a separate component, i.e., a 2K composition.

[0161] Aspect 70. The coating composition of any preceding aspect, wherein the coating composition is not an ecoat composition.

[0162] Aspect 71. A self- supported film and / or sheet formed from the coating composition of any preceding aspect.

[0163] Aspect 72. A method for using the coating composition, film and / or sheet of any of aspects 1-71 to coat a substrate, comprising applying to at least a portion of the substrate the composition, film, and / or sheet, and, when the composition is applied or the film and / or sheet is applied uncured or partially cured, curing after application to form a cured coating layer.

[0164] Aspect 73. A substrate prepared according to the method of aspect 72.

[0165] Aspect 74. The substrate of aspect 73, wherein the substrate comprises a vehicle.

[0166] Aspect 75. The substrate of aspect 73, wherein the substrate comprises a battery.

[0167] Aspect 76. The substrate of any of aspects 73-75, wherein the dry film thickness of the coating layer is 10 to 20,000 microns.

[0168] Aspect 77. The substrate of any of aspects 73-75, wherein the dry film thickness of the coating layer is 50 to 5,000 microns.

[0169] Aspect 78. The substrate of any of aspects 73-75, wherein the dry film thickness of the coating layer is 100 to 2,000 microns.

[0170] Aspect 79. A vehicle comprising an ecoat layer and the battery of aspect 75, wherein the ecoat layer is between a surface of the vehicle and the battery.

[0171] Aspect 80. The vehicle of aspect 79, wherein the ecoat layer is a fire-resistant ecoat.

[0172] Aspect 81. The vehicle of aspects 79 to 80, wherein the coating layer is on a surface of the battery.

[0173] Aspect 82. The vehicle of aspects 79 to 81, wherein the coating layer is on an inside surface of a lid of the battery.

[0174] Aspect 83. The vehicle of any of aspects 79 to 82 wherein the coating layer is on an inside surface of a box comprising the battery.

[0175] Aspect 84. The vehicle of aspect 74, wherein the coating layer comprises part of a coating stack.

[0176] Aspect 85. The vehicle of any of aspects 74 or 79 to 84, wherein the vehicle further comprises an additional fire-retardant material.

[0177] Aspect 86. A structure comprising the substrate of aspect 73.EXAMPLES

[0178] The following examples are intended to illustrate the disclosure and should not be construed as limiting the disclosure in any way.

[0179] Multiple coatings were prepared using the ingredients shown below. The base for each coating was prepared by dispersing all the components under a dispersion machine at highrotation speed until the sizes of the particles in the formulation were below 100 microns as measured with a Hcgman gauge. The hardener for each coating was prepared by dispersing all the components under a dispersion machine at high rotation speed until the sizes of the particles in the formulation were below 100 microns as measured with a Hegman gauge. Immediately prior to application, the base and hardener were mixed in a weight ratio of 4: 1 (base:hardener). The base and hardener were mixed by a mixer or spatula, until the color of the mixture became homogenous and lump-free. The coatings were applied to 150 x 75 x 0.8 mm electrocoated panels obtained from Etalon, and tested in accordance with the Blast Test.

[0180] As can be seen below, Formulations 1, 2, 6 and 7 represent the present disclosure while formulations 3, 4 and 5 lacked either the silicon component or both the silicon and phyllosilicate components. Specifically, formulations 3 and 4 had neither the silicon nor phyllosilicate components, while formulation 5 was without the silicon component.Formulation 1:Formulation 1-baseComponent Trade name Weight% in setBis-phenol A diglycidyl ether EP1KOTE 862110.4Cashew nutshell liquid RO YOXY RAD-91320.3Silicone Resin SILRES IC 900318.8Castor oil derivative THIXATROL ST40.1Ammonium polyphosphate EXOLIT AP 42254.4Zinc borate C-TEC CT-ZB 4006 14.0Kaolinite Kaolin723.3Phosphoric acid derivate DISFLAMOLL TP812.31Hexion2Gabriel performance products3Wacker4Elementis Specialties5Clariant AG6R J Marshall Co7Alroko GmbH & Co KG8LanxessFormulation 1 -hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 140995.5Castor oil derivative THIXATROL ST 4.0Silica SILICA105.0 Attapulgite ATTAGEL 50111.9HuntsmanSibclco1BASFFormulation 2:Formulation 2-baseComponent Trade name Weight% in set Bis-phenol A diglycidyl ether EPIKOTE 862 8.5 Cashew nutshell liquid ROYOXY RAD-913 0.2 Silicone Resin SILRES IC 900 24.4 Castor oil derivative THIXATROL ST 0.9 Ammonium polyphosphate EXOLIT AP 422 6.1Zinc borate C-TEC CT-ZB 4006 10.0 Kaolinite Kaolin 17.3 Phosphoric acid derivate DISFLAMOLL TP 12.1 Titanium Dioxide TLPURE R-706120.5The Chemours Company LLCFormulation 2-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 5.8Castor oil derivative THIXATROL ST 6.1Silica SILICA 4.2 Attapulgite ATTAGEL 50 3.9Formulation 3:Formulation 3-baseComponent Trade name Weight% in set Bis-phenol A diglycidyl ether EPIKOTE 862 16.3 Cashew nutshell liquid ROYOXY RAD-913 7.6 Castor oil derivative THIXATROL ST 0.2 Ammonium polyphosphate EXOLIT AP 422 6.1Zinc borate C-TEC CT-ZB 400 19.3 Melamine Recrystallized melamine138.6 Phosphoric acid derivate DISFLAMOLL TP 17.6Fisher ScientificFormulation 3-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 10.5 Castor oil derivative THIXATROL ST 7.0 Melamine Recrystallized melamine 4.9 Attapulgite ATTAGEL 50 1.9Formulation 4:Formulation 4-baseComponent Trade name Weight% in set Bis-phenol A diglycidyl ether EPIKOTE 862 22.7 Cashew nutshell liquid ROYOXY RAD-913 7.6 Castor oil derivative THIXATROL ST 1.1 Ammonium polyphosphate EXOLIT AP 422 7.5Zinc borate C-TEC CT-ZB 400 8.7 Melamine Recrystallized melamine 3.2Phosphoric acid derivate DISFLAMOLL TP 22.4Titanium dioxide TI-PURE R-706 8.5Formulation 4-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 5.8Castor oil derivative THIXATROL ST 6.1Melamine Recrystallized melamine 2.6Attapulgite ATTAGEL 50 3.9

[0181] Test result showed that panels with formulation 1 and 2 exhibited maximum backside temperature below 200°C and the electrocoat layer did not catch fire, while panels with formulation 3 and 4 exhibited maximum backside temperature above 400°C with the electrocoat layer catching fire during the testing.Formulation 5:Formulation 5 - baseComponent Trade name Weight% in setBis-phenol A diglycidyl ether EPIKOTE 862 14.3Cashew nutshell liquid ROYOXY RAD-913 3.2Castor oil derivative THIXATROL ST 0.2Ammonium polyphosphate EXOLIT AP 422 6.1Zinc borate C-TEC CT-ZB 400 11.3Kaolinite Kaolin 25.4Phosphoric acid derivate DISFLAMOLL TP 15.6Formulation 5-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 10.5Castor oil derivative THIXATROL ST 6.5Silicate SILICA 5.0Attapulgite ATTAGEL 50 1.9Formulation 6:Formulation 6-baseComponent Trade name Weight% in setBis-phenol A diglycidyl ether EPIKOTE 862 8.5Cashew nutshell liquid ROYOXY RAD-913 6.2Silicone Resin SILRES IC 900 15.5Castor oil derivative THIXATROL ST 2.2Ammonium polyphosphate EXOLIT AP 422 6.1Zinc borate C-TEC CT-ZB 400 14.1Kaolinite Kaolin 17.3Phosphoric acid derivate DISFLAMOLL TP 10.1Formulation 6-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 5.8Castor oil derivative THIXATROL ST 6.1Silica SILICA 4.2Attapulgite ATTAGEL 50 3.9

[0182] Test results showed that panels with formulation 6 exhibited maximum backside temperatures below 300°C and the electrocoat layer did not catch fire, while panels with formulation 5 exhibited maximum backside temperatures above 500°C with electrocoat layer catching fire during the testing. This comparison further showed that the silica component and phyllosilicate component, without the silicon component, did not result in a coating with antiblast properties.Formulation 7:Formulation 7-baseComponent Trade name Weight% in setBis-phenol A diglycidyl ether EPIKOTE 862 8.5Cashew nutshell liquid ROYOXY RAD-913 0.2Silicon Resin SILRES IC 900 28.6Castor oil derivative THIXATROL ST 0.9Ammonium polyphosphate EXOLIT AP 422 6.1Zinc borate C-TEC CT-ZB 4006 10.0Kaolinite Kaolin 17.3Phosphoric acid derivate DISFLAMOLL TP 12.1Titanium Dioxide TI-PURE R-706 0.5Formulation 7-hardenerComponent Trade name Weight% in set Polyamide amine ARADUR 1409 5.8Castor oil derivative THIXATROL ST 6.1Attapulgite ATTAGEL 50 3.9

[0183] Formulation 7 was the same as formulation 2 with some modification of amounts and without the silica component in the hardener. The panels coated with formulation 7 exhibited maximum backside temperatures below 300°C and the electrocoat layer did not catch fire. This demonstrates that formulations with the silicon component and the phyllosilicate component are effective, and that an added silica component (in formulation 2) can help to decrease the backside temperature of the panel.

[0184] Whereas particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the disclosure as defined in the appended claims.

Claims

What is claimed is:

1. A coating composition, comprising:a) a film forming component;b) a silicon component; andc) a phyllosilicate component;wherein the silicon component and the phyllosilicate component are different and wherein, a coating layer deposited from the composition, when cured to a dry film thickness of 2 mm + / - 0.5 mm, has anti-blast properties.

2. The coating composition of claim 1, wherein the film-forming component comprises a film-forming resin comprising an epoxy resin and a curing agent comprising a polyamine.

3. The coating composition of any preceding claim, wherein the composition further comprises a silica component.

4. The coating composition of any preceding claim, wherein the composition further comprises a silica component comprising a silica and / or a silicate particulate material and / or dispersions and / or solutions thereof.

5. The coating composition of any preceding claim, wherein the silicon component comprises a silicone resin and / or a siloxane.

6. The coating composition of any preceding claim, wherein the silicon component is present in a range of 10 to 40 wt.% or 15 to 25 wt.%, with wt.% based on the total weight of the composition.

7. The coating composition of any preceding claim, wherein the phyllosilicate component comprises clay, kaolin, and / or kaolinite.

8. The coating composition of any preceding claim, wherein the phyllosilicate component is present in a range of 10 to 50 wt.% or 15 to 25 wt.%, with wt.% based on the total weight of the composition.

9. The coating composition of any preceding claim, further comprising a colorant, a phosphate source, a borate source, a zinc source, an acid source, and / or a reinforcing filler.

10. The coating composition of any preceding claim, wherein the composition is substantially free, essentially free, and / or completely free of a borate source, alkyl phosphorus acid(s), melamine, ethylenically unsaturated monomer or residues thereof, a surfactant, piperazine salt(s), a reinforcing filler, TiO . a gas source, and / or a solvent.

11. A self- supported film and / or sheet formed from the coating composition of any preceding claim.

12. A method for using the coating composition and / or the film and / or sheet of Claims 1-11 to coat a substrate, comprising applying the composition, film, and / or sheet to at least a portion of the substrate and, when the composition is applied, or the film and / or sheet is applied uncured or partially cured, curing occurs after application to form a cured coating layer.

13. A substrate coated according to the method of Claim 12.

14. The substrate of Claim 13, wherein the substrate has an ecoat applied thereto, such as a fire-resistant ecoat, prior to application of the composition, film and / or sheet.

15. An article comprising the substrate of Claim 13 or 14.

16. The article of Claim 15, wherein the article comprises a battery.

17. The article of Claim 15, wherein the article comprises a vehicle comprising a battery.

18. A vehicle housing the battery of Claim 16.

19. The vehicle of Claim 17 or 18, wherein the vehicle has a surface coated at least in part with a fire-resistant ecoat, and / or a fire-retardant adhesive, sealant, gap filler, pottant, and / or encapsulant, including one formed from a composition comprising a fire retardant, and wherein the fire-resistant ecoat and / or fire-retardant adhesive, sealant, gap filler, pottant, and / or encapsulant, is between the surface and the battery.

20. The article of Claim 15, wherein the article comprises a structure.

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