Non-intumescent coatings having dielectric resistance

Abstract

Non-intumescent coatings having dielectric resistance are disclosed, as are methods for using such compositions and substrates coated with same.

Description

NON-INTUMESCENT COATINGS HAVING DIELECTRIC RESISTANCECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 646,011 filed May 13, 2024; U.S. Provisional Patent Application No. 63 / 659,979 filed June 14, 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 a non-intumescent coating composition having dielectric resistance, to a method for using the composition to coat a substrate, to a substrate coated with said composition, and to an article comprising said substrate, including energy storage devices and vehicles.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. Improved protective coatings, including those having improved dielectric resistance for energy storage devices, are therefore desired.SUMMARY

[0004] The present disclosure is directed to a non-intumescent coating composition comprising a film forming component and a phyllosilicate component, wherein a cured coating layer deposited from the composition, after exposure to the Flame Test, produces a coating charhaving a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test.

[0005] Methods of using the coating compositions according to the present disclosure and / or a film and / or sheet formed therefrom, 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 non-intumescent coating composition comprising a) a film-forming component; and b) a phyllosilicate component; wherein a cured coating layer deposited from the composition, after exposure to the Flame Test, produces a coating chai-having a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test. 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 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 non-intumescent coating layer having dielectric resistance. “Dielectrically resistant coatings” and like terms as used herein refer to coatings that pass the Flame Test and the Dielectric Strength Test. The “Flame Test” is run by applying coating composition to one side of a 1.2 mm thick steel panel and curing the composition at 90°C for over two hours to a dry film thickness of 600 microns + / - 100 microns. The coated side of the steel is exposed to thermal output at 1200 ± 50°C with 2 bar gas pressure for five minutes; if, after five minutes exposure to the flame, the opposite surface (that is, the uncoated surface of the steel panel) is at a temperature of 350°C or lower, the coating has passed the Flame Test. The coating chai’ is then subjected to the “Dielectric Strength Test”, wherein the dielectric strength of the char is measured by a SEFELEC Dielectrimeter RMG12AC-DC in accordance with ASTM D 149-09 Hipot test. “Coating char” or simply “char” and like terms as used below refer to that portion of the coating that remains after the Flame Test. Although “chai-” usually refers to the portion of the coating that remains adhered to the metal, it may also be described as having fallen off the metal.

[0008] Coatings deposited from the present coating composition are non-intumescent. “Non-intumcsccnt” and like terms, when used in reference to the present coatings, means that the coatings undergo expansion of no more than 5 times their dry film thickness upon exposure to the thermal output described above, such as below 3 times or below 1 time expansion. This expansion is significantly less than other coatings proposed for use with battery components, which may expand by 20 times or more of their dry film thickness.

[0009] 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. If applied to a battery used in an electric vehicle, the present coatings (or sheets / films made from the same) may contain excessive heat and / or fire within the battery and keep the heat / 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 thermal insulation of the present coatings (as indicated by passing the Flame 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.

[0010] 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, film former, and base may all be used interchangeably herein. Crosslinker, curing agent and hardener may all be used interchangeably herein. Any film-forming 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°C) or elevated temperature (i.e., greater than 50°C). The coating compositions of the present disclosure may specifically exclude electrodepositable 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.

[0011] 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, phenolicresins, urea-formaldehyde resins, polyimide resins, melamine resins, polyester resins, and cyanate resins. Among these resins, epoxy resins, acrylic resins, polyurethane resins and / or resins comprising siloxane and / or silane are particularly suitable.

[0012] Film-forming resins used according to the present disclosure contain one or more functional groups that either 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 groups functional groups, and combinations thereof.

[0013] 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 is not necessary in the present compositions.

[0014] 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.

[0015] 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 measured 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.

[0016] 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-cyclohcxanc diol, 1,4-cyclohcxanc diol, 2,2-bis(4-hydroxycyclohexy l)propane, 1 , 1 -bis(4-hydroxy cyclohexyl)ethane, 2-methyl- 1 , 1 -bis(4-hydroxycyclohexyl)propane, 2,2-bis(4- hydroxy-3-tert-butylcyclohexyl)propane, 1,3-bis(hydroxymethyl)cyclohexane and l,2-bis(hydroxymethyl)cyclohexane. 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] Linear polyesters may be more suitable than branched polyesters for use herein. Acid-functional polyesters can be prepared by the polycstcrification of an organic polycarboxylic acid or anhydride thereof with an organic polyol. The polycarboxylic acids and polyols can be aliphatic or aromatic dibasic acids and diols.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] According to the present disclosure, a polyester used to make the epoxyfunctional adduct may be prepared from a polycarboxylic acid component comprising a polycarboxylic acid or mixture of acids having from 7 to 16 carbon atoms and a polyol component comprising a portion of diethylene glycol.

[0026] 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.

[0027] 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.

[0028] 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, ally 1-3, 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.

[0029] 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.

[0030] 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-cyanoethyl acrylonitrile, fumaronitrile and combinations thereof, with acrylonitrile being particularly suitable.

[0031] Representative suitable vinyl-aromatic monomers include, for example, styrene, a-methylstyrene, p-methylstyrene, t-butylstyrene, and vinyltoluene.

[0032] 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.

[0033] 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.

[0034] The hydroxy alky l(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.

[0035] 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.

[0036] Vinyl ester monomers that can be used to prepare the epoxy-functional acrylic resin include vinyl acetate, vinyl proprionatc, vinyl butyrate, vinyl benzoate, vinyl-2-ethylhexanoate, vinyl stearate, and the vinyl esters of versatic acid.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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 resins, epoxy cresol novolacresins, epoxy functional (poly)magnesiums, epoxy functional polysulfides, epoxy-functional adducts of acid-functional polyesters and polycpoxidcs, for example, those that arc described above.

[0041] 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.

[0042] 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- (alkoxy methyl) acrylamides and N-(alkoxymethyl) methacrylamides.

[0043] 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.

[0044] 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 apolyisocyanate such that the OH / NCO equivalent ratio is greater than 1 :1 so that free hydroxyl groups arc present in the product.

[0045] 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.

[0046] 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.

[0047] 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, such as 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.

[0048] The polyepoxides that can be used for the reaction product of polyepoxide with (meth)acrylic acid can be those polyepoxides disclosed above.

[0049] In addition, or alternatively, to the beta-hydroxy ester of (meth) aery lie 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.

[0050] 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. Suitablecrosslinkers include, for example, polyamines, for example polyetheramines, polyamides, polycpoxidcs, aminoplast resins, phenolic resins, polyisocyanatcs, polythiols, and polyols, etc.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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, JEFF AMINE 600, JEFF AMINE 1000, JEFF AMINE 2005 and JEFF AMINE 2070, etc., can also be used.

[0055] 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. Polyethyleneaminecan include diethylenetriamine, tri ethylenetetraamine, tetraethylenepentaamine, etc., wherein the most commonly used is dicthylcnctriaminc. When polyamides arc used as the curing agent, it may impart one or more desirable properties to the coating, such as corrosion resistance, water resistance, and / or good flexibility.

[0056] 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.

[0057] 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.

[0058] In the coating composition of the present disclosure, the equivalent ratio of the combined functional groups / active hydrogen in the film-forming resin, such as epoxy groups if an epoxy resin is used, to the functional groups 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.

[0059] 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 40 wt.% or from 20 wt.% to 50 wt.%. Wt.% as reported herein is based on total solid weight of the composition unless indicated otherwise.

[0060] The coating compositions of the present disclosure comprise a phyllosilicate component, such as a plate-like phyllosilicate. As used herein, the term “phyllosilicate” refers to a group of minerals having sheets of silicates having a basic structure based on interconnected six membered rings of SiOri4tetrahedra 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 Si2O5'2. 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 thesilicate layer and / or the hydroxide ions. Examples of phyllosilicates pigments include the micas, chlorites, vermiculite, serpentine, talc, and the clay minerals. The shcct-likc 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 and smectite clay. Phyllosilicates may contribute to the chai’ strength. “Char Strength” refers to the ability of the char to resist pressure after thermal exposure as determined visually after, for example, exposure to the Flame Test.

[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 1.0 micron, such as at least 2.0 microns, such as at least 3.0 microns, such as at least 4.0 microns, such as at least 5.0 microns. The phyllosilicate may have an average equivalent spherical diameter of 25.0 microns or less, such as 15.0 microns or less, such as 10.0 microns or less, such as 5.0 microns or less, such as 3.5 microns or less, such as 2.5 microns or less, such as 1.9 microns or less, such as 1.5 microns or less, such as 1.0 micron or less.

[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 are 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 bedetermined using a viscometer using any standard method. Accordingly, if rheology modifiers comprising phyllosilicates arc used in the present coatings, they arc not considered in the wt.% of the phyllosilicates.

[0063] The present coating compositions may 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 silicon resin, the resin may be part of the film-forming component; that is, the silicon 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, or in a range of 10 to 40 wt.%, 20 to 30 wt.% or 15 to 25 wt.%, with wt.% based on the total weight of the composition. All our pail of the silicon component may be part of the film-forming component. That is, the film-forming component may comprise siloxane and / or silane in any of the above amounts or ranges. Silane may impart enhanced dielectric strength to the coating and also aid in adhesion. For clarity, when the film- forming component is said to comprise a certain wt.% siloxane and / or silane it means that wt.% of the moieties in the film forming component comprise siloxane and / or silane functionality or residue, with wt.% based on the total weight of the film forming component. “Residue” means the portion of the monomer that remains if the functionality may have been reacted during polymerization.

[0064] The coating compositions of the present disclosure may further comprise a silica component, such as silica powder, fumed silica, glass powder, silicon oxide powder, and combinations thereof. A “silica component” as used herein refers to any material that contributes silica and / or silicate in any form; a particularly suitable silica component comprises basalt, which can include both silica and silicate in approximately equal amounts. The silica component may be present in the coating compositions in an amount of 2 wt.% or greater, such as 5 wt.% or greater or 8 wt.% or greater. The silica component may be present in an amount of 20 wt.% or less, such as 15 wt.% or less, such as 10 wt.% or less, or in a range of 2-20 wt.%, 5-15 wt.% or 8-10 wt.%.

[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 in 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 TiO2. The minimization, if not elimination, of l iOz allows for coating compositions to be formulated so as 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 compositions of the present disclosure may further comprise a fire-retardant material. “Fire-retardant material” and like terms as used herein refers to materials that minimize the likelihood of a fire as compared with compositions lacking such materials, examples of which are metal oxides, including MgOH. Fire-retardant materials may also include those that release water when heated to 100°C or greater, such as hydrated metal oxides, including Al(0H)3 (“ATH”), Mg(OH)i, and Ca(OH)2. The coating composition may comprise the fire-retardant material in an amount of 5 wt.% or greater, such as 10 wt.% or greater, 15 wt.% or greater, or 20 wt.% or greater. The coating composition may comprise the fire-retardant material in an amount of 40 wt.% or less, such as 30 wt.% or less, or 25 wt.% or less, or 15 wt.% or less. The amount of fire-retardant material may range from 5 to 30 wt.%, such as 5 to 15 wt.% or 10 to 15 wt.%.

[0067] 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. “Phosphate source” as used herein means any phosphorus-containing material that comprises phosphoric acid or condensation or dehydration products (including oxides) thereof, or salts, esters, amides or other derivatives of any of the foregoing. 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 PnChn+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 5 to 20 wt.%, from 5 to 15 wt.%, or from 10 to 50 wt.%. The phosphorous is believed to function as a char promoter in the present compositions. As used herein, a “char promoter” is a component that increases the amount of carboneous component (char) after bum as compared to the amount of chai’ produced from a coating without the chai’ promoter.

[0068] 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.

[0069] 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, or 30 wt.% or less, or 30 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.%.

[0070] The optional source of zinc (“zinc source”) can comprise a variety of materials. 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 char 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 underlyingsubstrate. 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.%.

[0071] 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.%.

[0072] 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 total amount 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.

[0073] 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 10wt.-% 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 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.

[0074] 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.%.

[0075] 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” means that 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 are 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.

[0076] 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.

[0077] Accordingly, the present disclosure is also directed to a non-intumescent coating composition comprising a) a film forming component; and (b) a phyllosilicate component, wherein the coating composition is substantially free, essentially free and / or completely free of a gas source, and wherein the coating composition may have, after exposure to the Flame Test, a dielectric resistance of at least 1 kV, as measured by the Dielectric Strength Test.

[0078] 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 a curing agent therefor in a second package (B), whereby all of the other components used in the coating composition are 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.

[0079] 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 Paswhen measured at room 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.

[0080] 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.

[0081] 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 ait, 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).

[0082] The present coatings and self-supporting sheets 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, sportsequipment 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.

[0083] 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.

[0084] 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 coating composition / 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 / sheets 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 / orpositioned adjacent to the substrate. “Applying” therefore includes placing a self-supported film and / or sheet adjacent to a surface of an article.

[0085] 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 cars, trucks, buses, tractors, harvesters, heavy duty equipment, vans, golf carts, 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.

[0086] 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).

[0087] 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 comprisecomposite, 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.

[0088] 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.

[0089] 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.

[0090] 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 present disclosure can be employed. The article may be, for example, a mobile phone, a tablet, or a laptop computer.

[0091] 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 thevehicle 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.

[0092] 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 Int’l 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.

[0093] 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” phyllosilicate, “a” silica component, 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:

[0094] Aspect 1. A non-intumescent coating composition comprising a film forming component and a phyllosilicate component, wherein a cured coating layer deposited from the composition, after exposure to the Flame Test, produces a coating char having a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test.

[0095] Aspect 2. A non-intumescent coating composition comprising a film forming component and a phyllosilicate component.

[0096] Aspect 3. The non-intumescent coating composition of aspect 1 or 2, wherein the film-forming component comprises an epoxy resin.

[0097] Aspect 4. The non-intumescent coating composition of any preceding aspect, wherein the film- forming component comprises more than one 1,2-epoxy moieties.

[0098] Aspect 5. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of a polyphenol.

[0099] Aspect 6. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of bisphenol A.

[0100] Aspect 7. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of bisphenol F.

[0101] Aspect 8. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a siloxane and / or silane.

[0102] Aspect 9. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a siloxane and / or silane in an amount of 1 to 20 wt.%, where wt.% is based on the total weight of the film-forming component.

[0103] Aspect 10. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a polyaminc.

[0104] Aspect 11. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a blocked curing agent.

[0105] Aspect 12. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a blocked polyisocyanate.

[0106] Aspect 13. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises a polyetheramine.

[0107] Aspect 14. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises 10 to 60 wt.% of the composition, based on total solid weight of the composition.

[0108] Aspect 15. The non-intumescent coating composition of any preceding aspect, wherein the film-forming component comprises 10 to 40 wt.% of the composition, based on total solid weight of the composition.

[0109] Aspect 16. The non-intumescent coating composition of any of aspects 1 to 14, wherein the film-forming component comprises 20 to 50 wt.% of the composition, based on total solid weight of the composition.

[0110] Aspect 17. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises a plate-like phyllosilicate.

[0111] Aspect 18. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises mica.

[0112] Aspect 19. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises vermiculite.

[0113] Aspect 20. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises talc.

[0114] Aspect 21. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises clay.

[0115] Aspect 22. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component comprises kaolin clay.

[0116] Aspect 23. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of at least 50 nm as determined using dynamic light scattering.

[0117] Aspect 24. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of at least 1.0 micron as determined using dynamic light scattering.

[0118] Aspect 25. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of at least 5.0 microns as determined using dynamic light scattering.

[0119] Aspect 26. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 25.0 microns or less as determined using dynamic light scattering.

[0120] Aspect 27. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 15.0 microns or less as determined using dynamic light scattering.

[0121] Aspect 28. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 10.0 microns or less as determined using dynamic light scattering.

[0122] Aspect 29. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 250 nm to 25.0 microns as determined using dynamic light scattering.

[0123] Aspect 30. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 1.0 to 15.0 microns as determined using dynamic light scattering.

[0124] Aspect 31. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component has an average equivalent spherical diameter of 5.0 to 10.0 microns as determined using dynamic light scattering.

[0125] Aspect 32. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 3 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0126] Aspect 33. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 5 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0127] Aspect 34. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 10 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0128] Aspect 35. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 40 wt.% or less, with wt.% based on the total solid weight of the composition.

[0129] Aspect 36. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 30 wt.% or less, with wt.% based on the total solid weight of the composition.

[0130] Aspect 37. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 25 wt.% or less, with wt.% based on the total solid weight of the composition.

[0131] Aspect 38. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 20 wt.% or less, with wt.% based on the total solid weight of the composition.

[0132] Aspect 39. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 3 to 25 wt.%, with wt.% based on the total solid weight of the composition.

[0133] Aspect 40. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 5 to 20 wt.%, with wt.% based on the total solid weight of the composition.

[0134] Aspect 41. The non-intumescent coating composition of any preceding aspect, wherein the phyllosilicate component is present in the coating composition in an amount of 10 to 25 wt.%, with wt.% based on the total solid weight of the composition.

[0135] Aspect 42. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 2 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0136] Aspect 43. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 5 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0137] Aspect 44. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 8 wt.% or greater, with wt.% based on the total solid weight of the composition.

[0138] Aspect 45. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 20 wt.% or less, with wt.% based on the total solid weight of the composition.

[0139] Aspect 46. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 15 wt.% or less, with wt.% based on the total solid weight of the composition.

[0140] Aspect 47. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 10 wt.% or less, with wt.% based on the total solid weight of the composition.

[0141] Aspect 48. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 2 to 20 wt.%, with wt.% based on the total solid weight of the composition.

[0142] Aspect 49. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 5 to 15 wt.%, with wt.% based on the total solid weight of the composition.

[0143] Aspect 50. The non-intumescent coating composition of any preceding aspect, wherein the composition comprises a silica component present in the coating composition in an amount of 8 to 10 wt.%, with wt.% based on the total solid weight of the composition.

[0144] Aspect 51. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a silica component.

[0145] Aspect 52. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising silica powder and / or fumed silica.

[0146] Aspect 53. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a silica component comprising basalt.

[0147] Aspect 54. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a borate source.

[0148] Aspect 55. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a phosphate source.

[0149] Aspect 56. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises ammonium polyphosphate.

[0150] Aspect 57. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises an acid source.

[0151] Aspect 58. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a zinc source.

[0152] Aspect 59. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises TiO2.

[0153] Aspect 60. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a fire-retardant material.

[0154] Aspect 61. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises metal oxide.

[0155] Aspect 62. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises hydrated metal oxide.

[0156] Aspect 63. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises ATH.

[0157] Aspect 64. The non-intumescent coating composition of any preceding aspect, wherein the composition further comprises a reinforcing filler.

[0158] Aspect 65. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of melamine.

[0159] Aspect 66. The non-intumescent coating composition of any of aspect 1 to 58 or 60 to 65, wherein the composition is substantially free, essentially free, and / or completely free of'TiO2.

[0160] Aspect 67. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a gas source.

[0161] Aspect 68. The non-intumescent coating composition of any of aspect 1 to 53 or 55 to 67, wherein the composition is substantially free, essentially free, and / or completely free of a borate source.

[0162] Aspect 69. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of alkyl phosphorous acid(s).

[0163] Aspect 70. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of ethylenically unsaturated monomer residues.

[0164] Aspect 71. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a surfactant.

[0165] Aspect 72. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a nonionic surfactant.

[0166] Aspect 73. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of silicate other than the phyllosilicate of the phyllosilicate component.

[0167] Aspect 74. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of layered silicates and / or aluminum silicates other than the phyllosilicate of the phyllosilicate component.

[0168] Aspect 75. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of piperazine salt(s).

[0169] Aspect 76. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of reinforcing fillers other than that provided by the phyllosilicate component.

[0170] Aspect 77. The non-intumescent coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of solvent.

[0171] Aspect 78. A non-intumescent coating composition comprising a) a film forming component; and (b) a phyllosilicate component, wherein the coating composition is substantially free, essentially free and / or completely free of a gas source.

[0172] Aspect 79. A non-intumescent coating composition comprising a) a film forming component; and (b) a phyllosilicate component, wherein the coating composition is substantially free, essentially free and / or completely free of melamine.

[0173] Aspect 80. The non-intumescent coating composition of any preceding aspect, wherein the coating composition is not an electrodepositable coating composition.

[0174] Aspect 81. A coating layer deposited from the non-intumescent coating composition of any preceding aspect.

[0175] Aspect 82. The coating layer of aspect 81, wherein the layer passes the Flame Test.

[0176] Aspect 83. The coating layer of aspects 81 and 82, wherein the chai’ produced by the Flame Test has a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test.

[0177] Aspect 84. A self- supported film and / or sheet formed from the nonintumescent coating composition of any of aspects 1 to 80.

[0178] Aspect 85. A method for using the coating composition of any of aspects 1 to 80 and / or the film and / or sheet of aspect 84 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.

[0179] Aspect 86. The method of aspect 85, wherein both the non-intumescent coating composition and the film and / or sheet is applied to a substrate.

[0180] Aspect 87. A substrate coated according to any of the methods of aspects 85 to 86.

[0181] Aspect 88. The substrate of aspect 87, wherein the substrate comprises a vehicle.

[0182] Aspect 89. The substrate of aspect 87, wherein the substrate comprises a battery.

[0183] Aspect 90. A vehicle comprising an ecoat layer and the battery of aspect 89, wherein the ccoat layer is between a surface of the vehicle and the battery.

[0184] Aspect 91. The vehicle of aspect 90, wherein the ecoat layer is a fire-resistant ecoat.

[0185] Aspect 92. The vehicle of aspects 90 to 91, wherein the cured coating layer, film and / or sheet is on a surface of the battery.

[0186] Aspect 93. The vehicle of any of aspects 90 to 92, wherein the cured coating layer, film and / or sheet is on an inside surface of a lid of the battery.

[0187] Aspect 94. The vehicle of any of aspects 90 to 93 wherein the cured coating layer, film and / or sheet is on an inside surface of a box comprising the battery.

[0188] Aspect 95. The vehicle of aspect 88, wherein the coating layer, film, and / or sheet comprises part of a coating stack.

[0189] Aspect 96. The vehicle of any of aspects 88 or 90-95, wherein the vehicle further comprises an additional fire-retardant material.

[0190] Aspect 97. The substrate of aspect 87, wherein the substrate comprises a structure.EXAMPLES

[0191] The following examples are intended to illustrate the disclosure and should not be construed as limiting the disclosure in any way.

[0192] The coating formulations as described below were each applied on 150 x 75 x 1.2 mm steel panels with airless spray application to a thickness of 600+100 micron. The coated panels were cured at 90°C over 2 hours for full cure and were tested against 1200±50°C torch fire on the coated side, with 2 bar gas pressure for 5 minutes, after which time the backside temperature was monitored. After the Flame Test, the chai-was subjected to the Dielectric Strength Test up to 6 kV voltage. The dielectric breakdown voltage with maximum 1 mA leakage current was recorded.Examples

[0193] The coating formulations were prepared using the ingredients shown in the respective tables; wt.% is reported based on the weight of both the base and the hardener (“weight % in set”). The base for each coating formulation was prepared by dispersing all the components under a dispersion machine at high rotation speed until the sizes of the particles inthe formulation were below 200 microns. The hardener for each coating formulation 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 200 microns. The dispersion speed and disperser plate size were 2000 rpm and 80 mm, respectively, with the container diameter of 180 mm. Immediately prior to application, the base and hardener were mixed in the relative amounts shown in the tables below. The base and hardener were mixed by a mixer or spatula, until the color of the mixture became homogenous and lump-free.Formulation 1: Comparative ExampleFormulation 1-base (base: hardener = 4:1)Component Trade name Weight% in set Bis-phenol F diglycidyl ether EPIKOTE 862130Cashew nutshell liquid ROYOXY RAD-91321.9Glass fiber CHOPVANTAGE 315631.0Castor oil derivative THIXATROL ST40.1 Ammonium polyphosphate EXOLIT AP 422540Titanium dioxide TI-PURE R-70667.01Westlake Chemical Corporation2Gabriel Performance Products3Nippon Electric Glass4Elementis Specialties5Clariant AG6The Chemours Company LLCFormulation 1- hardener (base: hardener = 4:1)Component Trade name Weight% in set (tris-2, 4, 6-dimethylaminomethyl ACCELERATOR 960- 171.0phenol)Polyamide amine ARADUR 140816Castor oil derivative THIXATROL ST 0.1 Attapulgite ATTAGEL 5O90.9 Melamine Recrystallized melamine102.07Huntsman8Huntsman9BASF10AllnexFormulation 2:Formulation 2-base (base: hardener = 7:3)Component Trade name Weight% in set Bis-phenol F diglycidyl ether EPIKOTE 862 30 Cashew nutshell liquid ROYOXY RAD-913 1.9 Glass fiber CHOPVANTAGE 3156 4.0 Castor oil derivative THIXATROL ST 0.1 Ammonium polyphosphate EXOLIT AP 422 12 Silica FUMED SILICA115.0 Magnesium hydroxide MgOH1212 Titanium dioxide TI-PURE R-706 1211Evonik12Wego Chemical GroupFormulation 2- hardener (base: hardener = 7:3)Component Trade name Weight% in set (tris-2, 4, 6-dimethylaminomethyl ACCELERATOR 960-11.0 phenol)Polyamide amine ARADUR 140 16 Castor oil derivative THIXATROL ST 0.1 Attapulgite ATTAGEL 50 0.9 Vermiculite Vermiculite Powder131213Global MinechemFormulation 3Formulation 3 - base (base: hardener = 5:3)Component Trade name Weight% in set Bis-phenol F diglycidyl ether EPIKOTE 862 10 Phosphorus-based flame retardant TCPP 4.9 Castor oil derivative THIXATROL ST 0.2Silicone resin SILIKOPON EF1434.9 Ammonium polyphosphate EXOLIT APP 422 5 Phyllosilicate Mica flake153.5Glass fiber CHOPVANTAGE 3156 414Evonik15Axim MicaFormulation 3 - hardener (base:hardener = 5:3)Component Trade name Weight% in set Silicone resin SILRES HP 20201627.3Silica Silica JYEG-12174.5 Organophilic phyllosilicates GARAMITE 1958180.5rheology additiveTitanium dioxide TI-PURE R-706 5.216Wacker17ZHENGZHOU JINYUAN MICROPOWDER18BYK

[0194] Although formulations 1 to 3 all suppressed the substrate temperature to below 350°C, the chai-of formulation 1, which lacked the phyllosilicate component, had a dielectric strength of less than 0.3 kV, while the char of formulation 2 had more than 1 kV of dielectric strength and the chai' of formulation 3 had more than 3 kV of dielectric strength. Both formulations 2 and 3 had a phyllosilicate component, and formulation 3 also included a silicon resin.

[0195] Panels coated with formulation 1 and 3 were also subjected to the Heat Test, in which the coating compositions were each applied to one side of a 1.0 mm thick aluminum panel with airless spray application to a thickness of 400+100 micron, then the coating was cured at 90°C over 2 hours for full cure. The coated panels were then exposed to 450 ± 50°C heat in a muffle furnace for 30 minutes. After this time, if no peel-off or obvious defect of the coatings on the panels was observed, the coating passed the Heat Test. The chai' was subjected to the Dielectric Strength Test up to 3 kV voltage. The dielectric breakdown voltage with maximum 0.1 mA leakage current was recorded.

[0196] As for the Heat Test result, cracks and pulverization were observed on the surface of the coatings for formulation 1, which lead to film pccl-off from the substrate. No peel-off or defects of the coatings on the panels are observed for formulation 3. The char following the Heat Test of formulation 1 had a dielectric strength of less than 0.3 kV, while the char of formulation 3 had more than 3 kV of dielectric strength.Formulation 4- base (base: hardener = 1:1)Component Trade name Weight% Bis-phenol F diglycidyl ether EPIKOTE 862 22 Tri(2-Chloroisopropyl) FYROL PCF197.0 PhosphateCastor oil derivative THIXATROL ST 0.1 Ammonium polyphosphate EXOLIT AP 422 12 Ammonium Pentaborate Ammonium pentaborate8.4 tetrahydrate20Organophilic phyllosilicates GAR AMITE 19580.5 rheology additive19ICL GROUP20SGTFormulation 4- hardener (base: hardener = 1:1)Component Trade name Weight% (tris-2, 4, 6-dimethylaminomethyl ACCELERATOR 960-11.0 phenol)Polyamide amine ARADUR 140 17 Cashew nutshell liquid ROYOXY RAD-913 2.6 Polyamide thixotrope DISPARLON 6500210.4 Muscovite Mica MICRONISED MICA SX3002215 Magnesium silicate talc TALC 325 MESH231421KUSUMOTO CHEMICALS, LTD.22LKAB MINERALS LTD.23HAICHENG FUCHANG MINING CO.Formulation 5- base (base: hardener = 1:1)Component Trade name Weight% Bis-phenol F diglycidyl ether EPIKOTE 862 22.3 Tri(2-Chloroisopropyl) Phosphate FYROL PCF 6.4 Castor oil derivative THIXATROL ST 0.3 Ammonium Pentaborate Ammonium pentaborate tetrahydrate 10 Magnesium silicate talc TALC 325 MESH 11Formulation 5- hardener (base: hardener = 1:1)Component Trade name Weight% (tris-2, 4, 6-dimethylaminomethyl phenol) ACCELERATOR 960-1 1.5 Polyamide amine ARADUR 140 17 Cashew nutshell liquid ROYOXY RAD-913 3.5 Polyamide DISPARLON 6500 0.4 Ammonium Polyphosphate EXOLIT AP 422 11 Muscovite Mica MICRONISED MICA11 SX300Magnesium silicate talc TALC 325 MESH 5.6

[0197] Both formulations, comprising a combination of phyllosilicates, suppressed the substrate temperature to below 35O°C and the char had a dielectric strength of greater than 1 kV.Formulation 6 - base (base: hardener = 4:1)Component Trade name Weight%Bis-phenol F diglycidyl ether EPIKOTE 862 23.4Epoxy functional silane SILQUEST A-187245.7Cashew nutshell liquid ROYOXY RAD-913 1.9Glass fiber CHOP VANTAGE 3156 1.0Castor oil derivative THIXATROL ST 0.1Ammonium polyphosphate EXOLIT AP 422 18.5 Magnesium silicate talc TALC 325 MESH 22.9 Titanium dioxide TLPURE R-706 7.424Momentive Performance Materials Inc.Formulation 6 - hardener (base: hardener = 4:1)Component Trade name Wcight% (tris-2, 4, 6-dimethylaminomethyl ACCELERATOR 960-11.0 phenol)Polyamide amine ARADUR 140 16 Castor oil derivative THIXATROL ST 0.1 Attapulgite ATTAGEL 50 0.9 Melamine Recrystallized melamine 2.0

[0198] Formulation 6, which included silane, suppressed the substrate temperature to below 350°C and the char had a dielectric strength of greater than 1 kV.Formulation 7: Comparative ExampleFormulation 7 - base (base: hardener = 4:1)Component Trade name Weight% Bis-phcnol F diglycidyl ether EPIKOTE 862 25Epoxy functional silane SILQUEST A- 187 5 Cashew nutshell liquid ROYOXY RAD-913 1.9Glass fiber CHOPVANTAGE 3156 1.0 Castor oil derivative THIXATROL ST 0.1 Ammonium polyphosphate EXOLIT AP 422 40 Titanium dioxide TLPURE R-706 7.0Formulation 7 - hardener (base:hardener = 4:1)Component Trade name Weight% (tris-2, 4, 6-dimethylaminomethyl ACCELERATOR 960-11.0 phenol)Polyamide amine ARADUR 140 16 Castor oil derivative THIXATROL ST 0.1 Attapulgite ATTAGEL 50 0.9 Melamine Recrystallized melamine 2.0Formulation 8 - base (base: hardener = 1:1)Component Trade name Weight% Bis-phenol F diglycidyl ether EPIKOTE 862 5 Epoxy functional silane SILQUEST A- 187 5 Tri(2-Chloroisopropyl)TCPP 4.5 PhosphateCastor oil derivative THIXATROL ST 0.1 Phyllosilicate Mica flake 4.5 Silicone resin SILIKOPON EF2522 Silica Silica JYEG-12 2.2 Magnesium silicate talc TALC 325 MESH 2.4 Glass fiber CHOPVANTAGE 3156 4.325TIANJIN ZHONGXIN CHEMTECH CO.Formulation 8 - hardener (base:hardener = 1:1)Component Trade name Weight% Silicone resin SILRES HP 2020 31.4 Amine resin DOMIDE G-650265 Silica Silica JYEG-12 6.0 Organophilic phyllosilicates GARAMITE 19580.7 rheology additiveTitanium dioxide TLPURE R-706 6.926KUKDO CHEMICAL

[0199] When tested by the Flame Test, both formulations 7 and 8 suppressed the substrate temperature to below 35O°C, but the char of formulation 7, which lacked the phyllosilicate component, had a dielectric strength of less than 0.3 kV, while the char of formulation 8 had more than 3 kV of dielectric strength. After the Heat Test, carbonization was observed and the coating partially peeled off from the substrate for formulation 7, while no expansion or defects in the coatings of formulation 8 were noticed. In addition to that, the chai' following the Heat Test of formulation 7 had a dielectric strength of less than 0.3 kV, while the char of formulation 8, which had both the phyllosilicate and silicone resin, had more than 3 kV of dielectric strength.

[0200] 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 non-intumescent coating composition comprising:a) a film forming component; andb) and a phyllosilicate component; wherein a cured coating layer deposited from the composition, after exposure to the Flame Test, produces a coating char having a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test.

2. A non-intumescent coating composition, comprising:a) a film forming component; andb) and a phyllosilicate component; wherein the coating composition is substantially free, essentially free and / or completely free of melamine; and / or substantially free, essentially free and / or completely free of TiCh; and wherein a cured coating layer deposited from the composition, after exposure to the Flame Test, produces a coating char having a dielectric resistance of at least 1 kV as measured according to the Dielectric Strength Test.

3. The coating composition of any preceding claim, wherein the phyllosilicate component comprises clay, talc, vermiculite, and / or mica.

4. The coating composition of any preceding claim, further comprising a silica component.

5. The coating composition of any preceding claim, further comprising one or more of a fire-retardant material, a borate source, a zinc source, an acid source, a reinforcing filler and / or TiO2.

6. The coating composition of any preceding claim, wherein the film-forming component comprises an epoxy resin and an amine crosslinker.

7. The coating composition of any preceding claim, wherein the film- forming component comprises a siloxane and / or a silane.

8. The coating composition of claim 7, wherein the siloxane and / or the silane is present in the composition in an amount of 1 to 20 wt.%, where wt.% is based on the total weight of the film-forming component.

9. The coating composition of any preceding claim, wherein the phyllosilicate is present in an amount of 3 to 25 wt.%, where wt.% is based on the total solid weight of the composition.

10. The coating composition of any preceding claim, wherein the composition is substantially free, essentially free, and / or completely free of one or more of the following: a borate source, alkyl phosphorus acid(s), a melamine, ethylenically unsaturated monomer residue(s), a surfactant, a non-ionic surfactant, silicates other than phyllosilicates from the phyllosilicate component, piperazine salt(s), a reinforcing filler, TiO 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 of any of claims 1-10 or the self- supported film and / or sheet of claim 11 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 occurs after application to form a cured coating layer.

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

14. An article comprising the substate of claim 13.

15. The article of claim 14, wherein the article comprises a vehicle comprising a battery.

16. The article of claim 14, wherein the article comprises a battery.

17. The article of claim 14, wherein the article comprises a structure.

18. A vehicle housing the battery of claim 16.

19. The vehicle of claim 15 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.

20. The vehicle of claim 19, wherein the coating composition, sheet and / or film is between a surface of the vehicle and the battery.

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