Protective coatings having heat resistance

Abstract

Protective coatings comprising a film forming component and a basalt flake component are disclosed.

Description

PCT / US26 / 17627 04 March 2026 (04.03.2026)PROTECTIVE COATINGS HAVING HEAT RESISTANCE FIELD

[0001] The present disclosure is directed to protective coating compositions comprising a film-forming component, and a basalt flake component, to methods for using the compositions to coat a substrate, to substrates coated according to the method, and to articles comprising said substrate, including energy storage devices.BACKGROUND

[0002] 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 heat resistance for energy storage devices, are therefore desired.SUMMARY

[0003] The present disclosure is directed to a protective coating composition comprising a) a film-forming component; and b) a basalt flake component. The compositions can be formed into a self-supporting film and / or sheet.

[0004] Methods of using the coating compositions according to the present disclosure and / or a film or sheet formed therefrom to coat a substrate, and substrates coated thereby, as well as articles comprising such coated substrates, are also within the scope of the present disclosure, including battery components, batteries, and other energy storage devices.DETAILED DESCRIPTION

[0005] The present disclosure is directed to a protective coating composition comprising a) a film-forming component and b) a basalt flake component. 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 bePCT / US26 / 17627 04 March 2026 (04.03.2026)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 interchangeably herein and refer to the ability of at least a portion of the polymerizable and / or crosslinkable components to undergo a reaction.

[0006] The present coating compositions can be used to form a protective coating layer having heat resistance. “Protective coatings” and like terms as used herein refer to coatings that pass the Flame 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 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 forty minutes; if, after forty minutes exposure to the flame, the opposite surface (that is, the uncoated surface of the steel panel) is at a temperature of 440°C or lower, the coating has passed the Flame 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 “char” 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.

[0007] The coating compositions according to the present disclosure are particularly suitable for the surfaces of energy storage devices, especially the inside surfaces of such devices, and most especially the inside lid of such devices. If applied to a battery used in an electric vehicle, the present coatings (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.

[0008] 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 therefor. 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 withPCT / US26 / 17627 04 March 2026 (04.03.2026)itself, that is, undergo a self-crosslinking reaction, or can react with a crosslinker to form a film. Such reactions may occur at ambient (20°C + / - 5°C) or elevated (30°C or greater) temperature.

[0009] Any suitable resin or combination of resins can be used in the film-forming component, including, but not limited to, epoxy resins, acrylic resins, siloxane resins, polysiloxane resins, silane resins, polyurethane resins, polyurea resins, polyvinyl resins, phenolic resins, urea-formaldehyde resins, polyimide resins, melamine resins, polyester resins, and cyanate resins. Among these resins, epoxy resins, acrylic resins, polyurethane resins, and / or resins comprising siloxanes and / or silanes are particularly suitable.

[0010] 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.

[0011] 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 are capable of reacting with each other, the resin is considered self-crosslinking and the presence of a curing agent is not necessary in the present compositions.

[0012] The resin may contain a combination of functional groups that are capable of reacting with each other (self-crosslinking) and functional groups that are reactive with the functional groups of the 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.

[0013] Suitable epoxy resins for use in the present disclosure comprise at least one poly epoxide. The polyepoxide typically has more than one 1,2-epoxy group. The epoxy equivalent weight of the poly epoxide may range from 80 to 6000 g / eq, such as 100 to 700 g / eq.PCT / US26 / 17627 04 March 2026 (04.03.2026)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.

[0014] 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 polyepoxides are, for example, polyglycidyl ethers of polyphenols, such as 2,2-bis(4-hydroxyphenyl)propane (bisphenol A), resorcinol, hydroquinone, benzenedimethanol, phloroglucinol, bisphenol F, and catechol; or polyglycidyl ether of polyols, such as alicyclic polyols, such as 1,2-cyclohexane diol, 1,4-cyclohexane diol, 2,2-bis(4-hydroxycyclohexyl)propane, l,l-bis(4-hydroxycyclohexyl)ethane, 2-methyl-l,l-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(oxy ethylene) glycol, poly(oxypropylene) glycol, and neopentane diol.

[0015] 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.

[0016] 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, 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.

[0017] 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,PCT / US26 / 17627 04 March 2026 (04.03.2026)Ludwigshafen, Germany, and rubber-modified polyepoxide resins such as the product prepared from a polyglycidyl ether of bisphenol A and an acid-functional polybutadiene.

[0018] 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 poly epoxide. 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.

[0019] Linear polyesters may be more suitable than branched polyesters for use herein. Acid-functional polyesters can be prepared by the polyesterification of an organic polycarboxylic acid or anhydride thereof with an organic polyol. The poly carboxylic acids and polyols can be aliphatic or aromatic dibasic acids and diols.

[0020] 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.

[0021] 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.

[0022] 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 acidsPCT / US26 / 17627 04 March 2026 (04.03.2026)(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.

[0023] According to the present disclosure, a polyester used to make the epoxyfunctional adduct may be prepared from a polycarboxylic acid component comprising a poly carboxylic acid or mixture of acids having from 7 to 16 carbon atoms and a polyol component comprising a portion of diethylene glycol.

[0024] 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.

[0025] 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.

[0026] Suitable epoxy-functional ethylenically unsaturated monomers include, for example, glycidyl (meth)acrylate, allyl glycidylether, vinyl glycidylether, vinyl cyclohexene oxide, limonene oxide, 2-ethylglycidylacrylate, 2-ethylglycidylmethacrylate, 2-(n-propyl)glycidylacrylate, 2-(n-propyl)glycidylmethacrylate, 2-(n-butyl)glycidylacrylate, 2-(n-butyl)glycidylmethacrylate, glycidylmethylmethacrylate, glycidylacrylate, (3',4'-epoxyheptyl)-2-ethylacrylate, (3',4'-epoxyheptyl)-2-ethylmethacrylate, (6',7'-epoxyheptyl)acrylate, (6',7'-epoxyheptyl)methacrylate, allyl-3,4-epoxyheptylether, 6,7-epoxyheptylallylether, vinyl-3, 4-epoxyheptylether, 6,7-epoxyheptylvinylether, o-vinylbenzylglycidylether, m-vinylbenzylglycidylether, p-vinylbenzylglycidylether, 3-vinyl cyclohexene oxide, alpha-methyl glycidyl methacrylate, 3, 4-epoxy cyclohexylmethyl (meth)acrylate and combinations thereof.

[0027] 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; hydroxyalkyl esters of ethylenicallyPCT / US26 / 17627 04 March 2026 (04.03.2026)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.

[0028] 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.

[0029] Representative suitable vinyl-aromatic monomers include, for example, styrene, a-methyl styrene, p-methylstyrene, t-butyl styrene, and vinyltoluene.

[0030] 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.

[0031] 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.

[0032] The hydroxy alkyl(meth)acrylate monomers that can be used for the preparation of the epoxy-functional acrylic resin include, for example, hydroxyalkyl acrylate and methacrylate monomers based on ethylene oxide, propylene oxide and higher alkylene oxides or mixtures thereof. Examples are hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethylPCT / US26 / 17627 04 March 2026 (04.03.2026)methacrylate, hydroxypropyl methacrylate and hydroxybutyl acrylate. Particularly suitable is 2-hydroxy ethyl (meth)acrylate.

[0033] 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.

[0034] Vinyl ester monomers that can be used to prepare the epoxy-functional acrylic resin include vinyl acetate, vinyl proprionate, vinyl butyrate, vinyl benzoate, vinyl-2-ethylhexanoate, vinyl stearate, and the vinyl esters of versatic acid.

[0035] 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, acrylamidom ethyl 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.

[0036] 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- 1,2-butadiene, 2-chloro-l,3-butadiene, 1,3 -pentadiene, 1,3-hexadiene, 2,4-hexadiene, 1,3 -octadiene, 2-methyl-l,3-pentadiene, 2,3-dimethyl-l,3-pentadiene, 3.4-dimethyl- 1,3 -hexadiene, 2, 3-diethyl-l, 3-butadiene, 4,5-diethyl-l,3-octadiene, 3-butyl-l,3-octadiene, 3,7-dimethyl-l,3,6-octatriene, 2-methyl-6-methylene-l,7-octadiene, 7- methyl-3-methylene-l,6-octadiene, 1,3,7-octatriene, 2-ethyl-l, 3-butadiene, 2-amyl-l,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, 7,11 -dimethyl-3-methylene- 1,6,10-dodecatriene, 2,6-dimethyl-2,4,6-octatriene, 2-phenyl- 1,3 -butadiene and 2-methyl-3-isopropyl-l, 3-butadiene and 1,3-cyclohexadiene and combinations thereof.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0037] 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.

[0038] Suitable polyepoxy-functional compounds used according to the present disclosure may include, for example, diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, resorcinol diglycidyl ether, epoxy phenol novolac resin, epoxy cresol novolac resins, epoxy functional (poly)magnesiums, epoxy functional polysulfides, epoxy-functional adducts of acid-functional polyesters and polyepoxides, for example, those that are described above.

[0039] 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 4 to 18 or 1 to 4 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.

[0040] 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 hydroxyalkyl acrylates and methacrylates, typically having 2 to 4 carbon atoms in the hydroxyalkyl group, such as hydroxyethyl acrylate, hydroxypropyl acrylate, 4-hydroxybutyl acrylate, hydroxy-functional adducts of caprolactone and hydroxyalkyl acrylates, and corresponding methacrylates, as well as the beta-hydroxy ester-functional monomers described below. The acrylic polymer can also be prepared with N-(alkoxymethyl) acrylamides and N-(alkoxymethyl) methacrylamides.

[0041] 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 atPCT / US26 / 17627 04 March 2026 (04.03.2026)least 5 carbon atoms that are not polymerizable with the ethylenically unsaturated acid functional monomer.

[0042] The film forming resin used in the present disclosure can also comprise polyurethane. Among the polyurethanes that can be used are polymeric polyols that are prepared by reacting polyester polyols or acrylic polyols, such as those mentioned above, with a polyisocyanate such that the OH / NCO equivalent ratio is greater than 1 : 1 so that free hydroxyl groups are present in the product.

[0043] 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.

[0044] If the film-forming component comprises an epoxy resin and a poly amine 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.

[0045] 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.

[0046] The polyepoxides that can be used for the reaction product of polyepoxide with (meth)acrylic acid can be those polyepoxides disclosed above.

[0047] In addition, or alternatively, to the beta-hydroxy ester of (meth)acrylic acid (i) a (meth)acrylate-functional compound (ii) different from compound (i) may be present in the filmforming component. The viscosity of the composition of the present disclosure can be adjusted thereby. Thus, it is believed that the optional component (ii) functions as a reactive diluent. The optional (meth)acrylate-functional component (ii) of the present compositions may include, for example, poly(meth)acrylates of 1,4-butanediol, neopentyl glycol, ethylene glycol, 1,2-propanediol, 1,3 -propanediol, 2, 2, 4-trimethyl- 1,3 -pentanediol, 1,6-hexanediol, 1,4-cyclohexane dimethanol, para-xylene glycol, 1,4-cyclohexane diol, trimethylol ethane, trimethylolpropane,PCT / US26 / 17627 04 March 2026 (04.03.2026)pentaerythritol, polyether glycols, for example, poly(oxytetramethylene) glycol, poly(oxyethylene) glycol, poly(oxypropylene) glycol and combinations thereof.

[0048] As noted above, the film-forming component may also comprise a crosslinker. Any suitable crosslinker can be used according to the present disclosure, and will be chosen by one skilled in the art to react with the functional groups of the film-forming resin. Suitable crosslinkers include, for example, polyamines, for example polyetheramines, polyamides, polyepoxides, aminoplast resins, phenolic resins, polyisocyanates, polythiols, and polyols.

[0049] 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. Suitable curing agents of said type are, for example, blocked polyisocyanates. Thus, the term polyisocyanate as used herein encompasses blocked and free polyisocyanates. Latent or blocked curing agents are particularly suitable to provide single component compositions to secure sufficient storage stability and pot life prior to application and curing.

[0050] 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 diphenyl sulphone and the reaction product of a poly amine and an aliphatic fatty acid such as the series of materials sold by BASF under the trademark VERSAMID, which are particularly suitable.

[0051] 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.

[0052] As a curing agent, various polyetheramines, such as various JEFF AMINES available from Huntsman Corp., including, but not limited to, JEFF AMINE D-230, JEFF AMINEPCT / US26 / 17627 04 March 2026 (04.03.2026)D-400, JEFF AMINE 600, JEFF AMINE 1000, JEFFAMINE 2005 and JEFF AMINE 2070, can also be used.

[0053] Various polyamides can also be used. Generally, polyamides contain reaction products of dimer fatty acid and polyethyleneamine, and small amounts of monomer fatty acid. Dimer fatty acid is prepared by the oligomerization of monomer fatty acid. Polyethyleneamine can be any higher polyethyleneamine, such as diethylenetriamine, triethylenetetraamine, tetraethylenepentaamine, wherein the most commonly used is diethylenetriamine. When polyamides are used as the curing agent, it may impart one or more desirable properties to the coating, such as corrosion resistance, water resistance, and / or flexibility.

[0054] 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 Akzo Nobel Functional Chemicals GmbH&Co KG, Greiz, Germany.

[0055] 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. The film forming component of the present disclosure may comprise an epoxy resin and a polyamine crosslinker.

[0056] In the coating composition of the present disclosure, the equivalent ratio of the combined functional groups in the film-forming resin, such as epoxy groups if an epoxy resin is used, to the functional groups 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.

[0057] 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 15 wt.% or greater, 20 wt.% or greater, 30 wt.% or greater or 40 wt.% or greater. The coating composition may 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 15 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.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0058] The coating compositions of the present disclosure comprise a basalt flake component. “Basalt flake component” refers to the basalt flake product that is used in the composition. Basalt may occur naturally, for example, formed from volcanic lava and / or deposits in sills and dikes. Basalt morphology may comprise rocks, powders, fibers or flakes, such as plates, sheets, or cornflakes. As used herein, the term “basalt flake” refers to a group of minerals comprising basalt and having an aspect ratio of greater than 10, 15 or greater, or 20 or greater, such as 23 + / - 3, and less than 100, such as 50 or less, or 30 or less, such as greater than 10 to less than 100, 15 to 50, greater than 15 to less than 50, 20 to 30, or greater than 20 to less than 30, wherein the aspect ratio refers to the ratio of the width to the thickness of the flake, as determined using microscopy. It will be appreciated that the aspect ratio of basalt flakes differs significantly from other forms of basalt particles. For example, basalt fibers typically have an aspect ratio greater than 100, such as greater than 200, and up to 600; basalt powder typically has an aspect ratio of 10 or less. Basalt flakes are made from the raw material basalt ore; the ore is broken and melted at high temperature, processed by technology proprietary to the manufacturer, and dispersed to different particle sizes. Basalt flakes according to the present disclosure may comprise minerals such as plagioclase, pyroxene and olivine; they may comprise less than 50 weight percent silica, or 50 weight percent or greater silica. The basalt flakes of the disclosure may comprise silica and one or more silicates. It has been surprisingly discovered that basalt flakes may increase char strength, as compared to other forms of basalt, such as basalt fibers or basalt powder. “Char Strength” refers to the ability of the char that results after exposure to the Flame Test to resist pressure, and is determined visually after application of manual pressure.

[0059] The basalt flake may have a D50 particle size of 50-75 microns as determined using dynamic light scattering. For example, the basalt flake may have a D50 particle size of 50 microns or greater, 55 microns or greater, 60 microns or greater, 65 microns or greater, or 70 microns or greater. The basalt flake may have a D50 particle size of 75 microns or lower, 70 microns or lower, 65 microns or lower, 60 microns or lower, or 55 microns or lower. The basalt flake may have a D50 particle size in a range of any of the above-mentioned values such as from 50 to 75 microns, or 55 to 70 microns. All of the D50 values recited herein are based on volume; that is, they are Dv50.

[0060] The coating compositions of the present disclosure may comprise the basalt flake component in an amount of 5 wt.% or greater, such as 10 wt.% or greater, or 25 wt.% or lower,PCT / US26 / 17627 04 March 2026 (04.03.2026)such as 20 wt.% or lower or 15 wt.% or lower, such as 5 to 25 wt.%, 5 to 15 wt.%, or 10 to 20 wt.%. The amount of basalt flake component does not include basalt in any other form, such as powder or fiber, that may be used in the composition.

[0061] The coating compositions of the present disclosure may further 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 SiC>4’4tetrahedra 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 Si2O s’2. Phyllosilicates may comprise hydroxide ions located at the center of the tetrahedra and / or cations such as, for example, Fe+2, Mg+2, or Al+3, that form cation layers between the silicate sheets where the cations may coordinate with the oxygen of the silicate layer and / or the hydroxide ions.Examples of phyllosilicates pigments include mica, chlorites, vermiculite, serpentine, talc, and clay minerals. The sheet-like structure of the phyllosilicate pigment may result in particles having a plate-like structure, and such plate-like phyllosilicate may be used according to the present disclosure. The clay minerals include, for example, kaolin clay and smectite clay.

[0062] 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 as determined by microscopy, for example, at least 2:1. For example, the phyllosilicate may have an average equivalent spherical diameter of at least 50 nm, such as at least 0.2 microns, such as at least 0.4 microns, such as at least 0.6 microns, such as at least 1 micron, such as at least 2 microns, such as at least 3 microns, such as at least 4 microns, such as at least 5 microns. The phyllosilicate may have an average equivalent spherical diameter of no more than 25 microns, such as no more than 15 microns, such as no more than 10 microns, such as no more than 5 microns, such as no more than 3.5 microns, such as no more than 2.5 microns, such as no more than 1.9 microns, such as no more than 1.5 microns, such as no more than 1 micron.

[0063] The phyllosilicate may be present in the coating compositions in an amount of 3 wt.% or greater, such as 5 wt.% or greater or 10 wt.% or greater. The phyllosilicate may bePCT / US26 / 17627 04 March 2026 (04.03.2026)present in an amount of 40 wt.% or less, such as 30 wt.% or less, or 15 wt % or less, or in a range of 3 to 25 wt.%, or 5 to 15 wt.%. It will be appreciated that phyllosilicates are often found in rheology modifiers. In such applications, the phyllosilicates are often ground or pulverized. If rheology modifiers comprising phyllosilicates are used in the present coatings, they are not considered in the wt.% of the phyllosilicates.

[0064] The coating compositions of the present disclosure further comprise a phosphate source. “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, 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, coated or uncoated, represented by the formula (NH4)n+2 PnOsn+i, wherein n is an integer of at least 2; particularly suitable is when n is an integer of at least 50. The composition of the present disclosure may contain the phosphate source in an amount of 5 wt.% or greater, such as, 20 wt.% or greater, 25 wt.% or greater, 30 wt.% or greater, 35 wt.% or greater, or 40 wt.% or greater. The coating composition may comprise the phosphate source in an amount of 55 wt.% or less, such as 50 wt.% or less, 45 wt.% or less, 40 wt.% or less, or 35 wt.% or less. The coating composition may comprise the phosphate source in a range of any of the above values such as from 20 to 55 wt.%, from 20 to 35 wt.%, or from 35 to 45 wt.%.

[0065] The present coatings may also comprise a catalyst. If present, the catalyst may be latent, such as a blocked and / or an encapsulated catalyst. Suitable catalysts include amine-based catalysts, such as a guanidine, a substituted guanidine, a substituted urea, a melamine resin, a guanamine derivative, a cyclic tertiary amine, an aromatic tertiary amine, or combinations thereof. It will be understood that “guanidine,” as used herein, refers both to guanidine and derivatives thereof, some of which are listed below. Suitable catalysts include trimethylamine; tributylamine; N,N-bis(N,N-dimethyl-2-aminoethyl)methylamine; N,N-dimethylcyclohexylamine; N-methylmorpholine; N-ethylmorpholine; l,2-dimethyl-l,4,5,6-tetrahydropyrimidine; 1,4,5,6-tetrahydropyrimidine; l,8-diazabicyclo[5.4.0]undec-7-ene; 1,5,7-triazabicyclo[4.4.0]dec-5-ene; 7-methyl-l,5,7-triazabicyclo[4.4.0]dec-5-ene; 1,5-PCT / US26 / 17627 04 March 2026 (04.03.2026)diazabicyclo[4.3.0]non-5-ene; 6-(dibutylamino)-l,8-diazabicyclo(5,4,0)undec-7-ene; 1,4-diazabicyclo[2.2.2]octane; 7-azabicyclo[2.2.1]heptane; N, N-dimethylphenylamine; 4,5-dihydro-IH-imidazole; and guanidine-based catalysts such as guanidine, methylguanidine, dimethylguanidine, trimethylguanidine, tetramethylguanidine, pentamethylguanidine, methylisobiguanidine, dimethylisobiguanidine, tetramethylisobiguanidine, hexamethylisobiguanidine, heptamethylisobiguanidine, phenylguanidine, diphenylguanidine, butylbiguanide, 1-o-tolylbiguanide, 1-phenylbiguanide, l-methyl-3 -nitroguanidine, 1,8-bis(tetramethylguanidino)-naphthalene, and N,N,N',N'-tetramethyl-N"-[4-morpholinyl(phenylimino)methyl]guanidine, and cyanoguanidine. Representatives of suitable guanamine derivatives include alkylated benzoguanamine resins, benzoguanamine resins or methoxymethylethoxymethylbenzoguanamine. Suitable catalysts further include azoles, diazoles, triazoles, higher functional azoles, pyrrolidine, tropane, pyrrolizidine, piperidine, quinolizidine, indolizidine, pyridine, isoquinoline, oxazole, isoxazole, thiazole, quinazoline, acridine, quinoline, indole, imidazole, purine, phenethylamine, muscarine, benzylamines, derivatives of these compounds, or combinations thereof, e.g., the catalyst may comprise a guanidine, a guanidine derivative and / or an imidazole. Other suitable catalysts include ammonium salts, phosphines and / or phosphonium salts. If present, the coating composition may, for example, contain 0.1 wt.% or greater of the catalyst, such as 0.5 wt.% or greater or 1 wt.% or greater. If present, the coating composition may, for example, contain 5 wt.% or less of the catalyst, such as 3 wt.% or less or 2 wt.% or less. The coating composition may, for example, comprise the catalyst in an amount in a range of any of the above-mentioned values such as from 0.1 wt.% to 5 wt.%, from 0.5 wt.% to 3 wt.% or from 1 wt.% to 2 wt.%.

[0066] The coating layers deposited from the present compositions may be intumescent or non-intumescent. If intumescent, the coating composition may further comprise a gas source. A “gas source” refers to a compound providing an expansion gas upon thermal decomposition. The expansion gas serves to cause the protective composition to foam and swell when exposed to high temperature or flames hot enough to cause the evolution of gas. As a result of this expansion, the char that is formed is a thick, multicelled material that serves to insulate and protect the underlying substrate. Any suitable source of expansion gas may be used to cause intumescence in the coating layer deposited from the compositions of the present disclosure, such as a nitrogen-containing material. Examples of suitable nitrogen-containing materialsPCT / US26 / 17627 04 March 2026 (04.03.2026)include melamine, salts of phosphoric acid, guanidine, methylolated melamine, hexamethoxymethyl melamine, urea, dimethylurea, melamine pyrophosphate, dicyandiamide, guanylurea phosphate and glycine. “Melamine” as used herein refers to both melamine and melamine derivatives, several of which are named above, and generally refers to a component that contains one or more melamine moieties that will decompose at high temperatures, generally 200°C or greater, to form inert gas. Other conventional sources of expansion gas can also be used, such as those materials that liberate carbon dioxide. Examples are alkaline earth metals such as calcium carbonate or magnesium carbonate. Compounds that release water vapor as they decompose upon heating, for example calcium hydroxide, magnesium dihydroxide or aluminum trihydroxide, may also be used, as can expandable graphite. Other examples of such compounds are borate sources, such as boric acid and boric acid derivatives such as boric acid esters and metal borates. Certain latent catalysts, such as those listed above, can also provide a gas source. The gas source, such as melamine, may be used in the protective coating compositions of the present disclosure in an amount of 1 wt.% or greater, such as 2 wt.% or greater, or 3 wt.% or greater. The compositions according to the present disclosure can comprise the gas source, for example in an amount of 10 wt.% or less, 8 wt.% or less, 7 wt.% or less, or 5 wt.% or less. The composition may comprise the gas source in an amount in a range of any of the above-mentioned values such as from 1 to 10 wt.%, such as 3 to 7 wt.%.

[0067] A “non-intumescenf ’ coating layer according to the present disclosure means that the coatings undergo expansion of no more than 5 times their dry film thickness upon exposure to the thermal output of the Flame Test, such as below 3 times or below 1 time expansion. This expansion is significantly less than intumescent coatings, which may expand by 10 times or more, such as 15 times or more, or 20 times or more of their dry film thickness. A non-intumescent coating layer may be deposited from a coating composition that is free of a gas source. 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.

[0068] The coating compositions of the present disclosure may further comprise one or more additional additives, including a borate source, an aluminum source, a silica source, a zinc source, an acid source and / or reinforcing filler. “Borate source” as used herein means any boron-containing material that contains boric acid, or condensation or dehydration productsPCT / US26 / 17627 04 March 2026 (04.03.2026)(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. “Aluminum source” as used herein means any aluminum-containing material. The aluminum source may be an aluminum compound, in particular an inorganic aluminum compound. Suitable aluminum sources include, for example, aluminum hydroxide, aluminum oxide (alumina), aluminum chloride, aluminum salts, and combinations thereof. For instance, the aluminum source can comprise aluminum hydroxide and / or aluminum oxide. “Silica source”, as used herein, means any silicon-containing material that contains polysiloxane, silane, silicic acid, condensation or dehydration products (including oxides) thereof or salts or esters of any of the foregoing.Suitable silica sources include, for example, fumed silica or quartz, such as those having an average particle size below 150 pm as determined by laser diffraction, or a substance that contains silica such as bentone or kaolin. The basalt flake component, which may introduce silica to the composition, is not considered a “silica source” for purposes of the present disclosure unless indicated otherwise. That is, a “silica source” according to the present invention comprises one or more compounds other than the basalt flake component.

[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 20 wt.% or less, such as 19 wt.% or less, or 18 wt.% or less, or 15 wt.% or less. The coating composition may comprise the borate source in an amount in a range of any of the above-mentioned values such as from 5 wt.% to 20 wt.%, or from 6 wt.% to 15 wt.%, or from 9 wt.% to 15 wt.%. The coating composition of the present disclosure may contain the aluminum source, if used, in an amount of 0.1 wt.% or greater, such as 0.2 wt.% or greater, or 0.3 wt.% or greater, or 0.5 wt.% or greater, or 1 wt.% or greater, or 3 wt.% or greater, or 5 wt.% or greater. The coating composition may comprise the aluminum source in an amount of 10 wt.% or less, such as 9 wt.% or less, or 8 wt.% or less, or 5 wt.% or less, or 3 wt.% or less, or 1 wt.% or less, or 0.7 wt.% or less. The composition may comprise the aluminum source in an amount in a range of any of the above-mentioned values such as from 0.1 to 10 wt.%, such as 0.2 to 8 wt.% or from 0.3 wt.% to 1 wt.%. The coating composition of the present disclosure may contain thePCT / US26 / 17627 04 March 2026 (04.03.2026)silica source, if used, in an amount of 0.1 wt.% or greater, such as 0.2 wt.% or greater, or 0.3 wt.% or greater, or 0.4 wt.% or greater, or 0.5 wt.% or greater. The coating composition may comprise the silica source in an amount of 5 wt.% or less, such as 3 wt.% or less, or 2 wt.% or less, or 1 wt.% or less, or 0.8 wt.% or less. The composition may comprise the silica source in an amount in a range of any of the above-mentioned values such as from 0.1 to 5 wt.%, such 0.4 to 1 wt.%. As noted above, the basalt flake component may contribute silica to the present compositions; the amount of silica that may be contributed by the basalt flake component is not considered when determining the amount of silica in the present compositions.

[0070] The optional 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 Angstrom “A0” or below) structure in the char. The small cells of the char may provide better insulation of the substrate as they are better able to retain the char’s integrity and adhere to the substrate as compared to larger cells (such as above 50 A0, up to 100 A0). Thus, cracking of the char and its breaking away from the substrate are minimized and a greater measure of protection is afforded to the underlying substrate. Examples of suitable materials that are sources of zinc include zinc oxide, zinc salts, such as zinc borate and zinc phosphate, zinc carbonate, zinc metal, and combinations thereof. The zinc source, if used, may be used in an amount of 5 wt.% or greater, such as 10 wt.% or greater. The coating composition may comprise the zinc source in an amount of 40 wt.% or less, such as 30 wt.% or less. The coating composition may comprise the zinc source in an amount in a range of any of the above-mentioned values such as from 5 wt.% to 40 wt.%, or from 10 wt.% to 30 wt.%.

[0071] The optional acid source may comprise ammonium phosphate, ammonium polyphosphate, diammonium diphosphate, diammonium pentaborate, 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. The coating composition may comprise the acid source in an amount of 60 wt.% or less, such as 50 wt.% or less, or 40 wt.% or less. The coating composition may comprise the acid source in an amount in a range of any of the above-mentioned 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 sourcePCT / US26 / 17627 04 March 2026 (04.03.2026)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 glass microspheres and fibrous reinforcements. Examples of fibrous reinforcements include glass fibers, ceramic fibers, e.g., aluminum oxide / silicon oxide, graphite fibers, mineral fibers and basalt fibers, which can be used in an amount of 10.0 wt.% or less, such as 5 wt.% or less, such as 4 wt.% or less, or 2 wt.% or less, or in an amount of 0.1 wt.% or greater, such as 0.2 wt.% or greater, 0.5 wt.% or greater, or 1 wt.% or greater, or in a range of any of the above-mentioned values such as from 0.1 wt.% to 5 wt.% or from 1 wt.% to 4 wt.%.

[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 a total 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 total range of any of the above-mentioned values such as from 1 to 20 wt.%, such as 2 to 20 wt.% or 5 to 15 wt.%.

[0075] The coating compositions of the present disclosure may further comprise TiCh, such as in an amount of 3 wt.% or greater, such as 5 wt.% or greater or 10 wt.% or greater and may be present in any amount of 25 wt.% or less, such as 20 wt.% or less, or 15 wt.% or less, or in a range of 5-20 wt.% or 10-15 wt.%.

[0076] The compositions of the present disclosure may further comprise a fire-retardant material in addition to the phosphate source. “Fire-retardant material” and like terms as used herein refers to materials that minimize the likelihood of a fire as compared to the samePCT / US26 / 17627 04 March 2026 (04.03.2026)composition without the material, 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(0H)2, and Ca(0H)2. The coating composition may comprise the additional 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.%.

[0077] 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 including, but not limited to, layered silicate and metallic, such as aluminum, silicate(s), and piperazine salt(s), any of the above reinforcing fillers, TiCh, a gas source and solvent. “Substantially free” as used in this context means the composition comprises less than 3.0 wt.% of any of these compounds, “essentially free” means 1.0 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. As noted above, the coating compositions of the present disclosure may also be substantially free of a gas source. It will be appreciated that melamine can be a gas source and when the present compositions are substantially free, essentially free, or completely free of melamine the values are as described in this paragraph.

[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 compositionsPCT / US26 / 17627 04 March 2026 (04.03.2026)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 Pas when measured at ambient temperature and 0.1 s'1shear rate. It is particularly suitable that the composition be free of solvent other than that brought into the composition through one or more of its components and spray-applied. If desired, thinning can be accomplished with a variety of conventional solvents such as, xylene, methylene chloride, or 1,1,1 -tri chloroethane. 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. It has been surprisingly discovered that use of basalt flake allows for easier use of spray apparatus than other forms of basalt, such as basalt fiber, which tends to clog the nozzle.

[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, such as 600 + / - 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.

[0081] Alternatively, the compositions of the present disclosure can be formed into a self-supported film and / or sheet. The self-supported film and / or sheet may subsequently be cured to form a crosslinked self-supported film and / or sheet. In general, the compositions of the present disclosure can be formed into a film and / or sheet by any technique known to a person skilled in the art, for example a cast-molding process, by impregnating a mesh with the coating composition, and the like. The film and / or sheet can be cured to form a crosslinked selfsupported film and / or sheet that can then be applied to a substrate. It is also within the present disclosure that after the forming step the uncured or partially cured film and / or sheet is applied toPCT / US26 / 17627 04 March 2026 (04.03.2026)a substrate and then subsequently cured to obtain the coating layer according to the present disclosure.

[0082] The present coatings and self-supporting film and / or sheet can be applied to any substrates known in the art, for example, automotive substrates, marine substrates, industrial substrates, heavy-duty equipment, packaging substrates, lumber, wood flooring and furniture, apparel, electronics including housings and circuit boards and including consumer electronics such as housings for computers, notebooks, smartphones, tablets, televisions, gaming equipment, computer equipment, computer accessories, MP3 players, glass and transparencies, sports equipment and the like. These substrates can be, for example, metallic or non-metallic. Metallic substrates include metal sheet, tin, steel, tin-plated steel, chromium passivated steel, galvanized steel, aluminum, and aluminum foil. Metal sheet as used herein refers to flat metal sheet and coiled metal sheet, which is coiled, uncoiled for coating, and then re-coiled for shipment to a manufacturer. Non-metallic substrates include polymeric, plastic, polyester, polyolefin, polyamide, cellulosic, polystyrene, polyacrylic, polyethylene 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.

[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. The substrate may also be 3D printed.

[0084] The substrate can also be electrocoated prior to applying the composition / film / sheet. “Electrocoated” means a coating - an “ecoat” - has been depositedPCT / US26 / 17627 04 March 2026 (04.03.2026)through electro deposition. Such process and coatings for same are well known. Particularly suitable are the fire-resistant ecoats described below. The present composition / film / sheet may be deposited on top of the ecoat.

[0085] 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 by applying a coating layer from any of the coating compositions / films / sheets of the present disclosure to at least a portion of the substrate and, when the composition is applied, or the film and / or sheet is applied uncured or partially cured, curing after application to form a cured coating layer, to substrates prepared by this method, and articles comprising such substrates. The compositions / films / sheets of the present disclosure may be used with 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; accordingly, when reference is made herein to a substrate being “coated with”, or like terms, the present compositions, this includes coating by application of a film and / or sheet formed from the composition(s). The adhesive may be in the form of an adhesive layer on a surface of the film / sheet. A self-supporting film and / or sheet may also be positioned adjacent to the substrate. “Applying” therefore includes placing a self-supported film and / or sheet adjacent to a surface of an article.

[0086] Articles comprising the coated substrate are also within the present disclosure. 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 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.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0087] 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 / or 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).

[0088] The coating composition, film and / or sheet can be applied to any structural element of a battery to obtain a battery according to the present disclosure. The battery may comprise exterior wall elements defining a housing and optionally interior wall elements, wherein the coating or self-supported film or sheet is at least partially applied to the external and / or internal side of any of the exterior wall elements and / or to any side of any of the interior wall elements, if present. The exterior wall and / or interior wall elements may comprise composite, steel, aluminum and / or polycarbonate. The present coatings may be particularly suitable for use on the inside of a battery or other energy storage device, where space for a coating layer or film may be limited. This can prevent or at least minimize the likelihood of overheating of the substrate during a thermal runaway event.

[0089] The battery, in particular 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.

[0090] 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 betweenPCT / US26 / 17627 04 March 2026 (04.03.2026)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.

[0091] To provide fire protection for articles comprising a battery and their users, the coating composition, film and / or sheet may be applied 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.

[0092] As noted above, the article may be a vehicle such as a hybrid or electric car, bus or truck. In such vehicles it is common to position the battery, due to its weight, as a flat battery pack underneath the floor portion of the vehicle body, such as the car body. The coating composition, film and / or sheet of the present disclosure may be applied to the floor portion of the vehicle adjacent to the battery, such as between the battery and the vehicle body. In an event of a thermal runaway of the battery or a battery fire, the car body, especially the passenger cabin, would be protected by the coating layer / film / sheet of the present disclosure so that the battery box will resist flame, and any fire inside the battery box will not spread into the passenger cabin; heat-up of the passenger cabin may also be limited for a prolonged period of time so that the passengers can safely escape from the vehicle in case of such an incident.

[0093] 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-resistantPCT / US26 / 17627 04 March 2026 (04.03.2026)ecoat include those disclosed in U.S. Patent No. 10,697,081; U.S. Pub. No. 2023 / 044601 Al, Int’l Pub. No. 2021 / 127327A1; and Int’l Pub. No. 2022 / 133202 Al. Fire-retardant adhesives, sealants, gap fdlers, 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 fire-retardants to a substrate surface. Suitable examples include those disclosed above as well as those disclosed in Int’l Publ. No. 2021 / 211722A1, pars. 57-309; Int’l Publ. No. 2021 / 211183A1, pars. 44-178; Int’l Publ. No. 2021 / 211184A1, pars. 52-252; Int’l 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.

[0094] 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” basalt flake 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, epoxy includes polyepoxy, and isocyanate includes di-, tri-, and other poly isocyanates, isocyanurates, and dimers and trimers of isocyanate. 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.In the following, some non-limiting Aspects of the present disclosure are summarized:

[0095] Aspect 1. A protective coating composition comprising a) a fdm forming component and b) a basalt flake component.

[0096] Aspect 2. The protective coating composition of aspect 1, wherein the filmforming component comprises an epoxy resin.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0097] Aspect 3. The protective coating composition of aspect 1 or 2, wherein the filmforming component comprises more than one 1,2-epoxy groups per molecule.

[0098] Aspect 4. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of a polyphenol.

[0099] Aspect 5. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of bisphenol A.

[0100] Aspect 6. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a polyglycidyl ether of bisphenol F.

[0101] Aspect 7. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a siloxane and / or silane.

[0102] Aspect 8. The protective 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 9. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a polyamine.

[0104] Aspect 10. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a blocked curing agent.

[0105] Aspect 11. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a blocked polyisocyanate.

[0106] Aspect 12. The protective coating composition of any preceding aspect, wherein the film-forming component comprises a poly etheramine.

[0107] Aspect 13. The protective 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 14. The protective coating composition of any preceding aspect, wherein the film-forming component comprises 15 to 40 wt.% of the composition, based on total solid weight of the composition.

[0109] Aspect 15. The protective coating composition of any preceding aspect, wherein the film-forming component comprises 20 to 50 wt.% of the composition, based on total solid weight of the composition.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0110] Aspect 16. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of 23 + / - 3.

[0111] Aspect 17. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has a D50 particle size of 50 microns or greater as determined using dynamic light scattering.

[0112] Aspect 18. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has a D50 particle size of 55 microns or greater as determined using dynamic light scattering.

[0113] Aspect 19. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has a D50 particle size of 75 microns or lower as determined using dynamic light scattering.

[0114] Aspect 20. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has a D50 particle size of 70 microns or lower as determined using dynamic light scattering.

[0115] Aspect 21. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has a D50 particle size of 50 to 75 microns as determined using dynamic light scattering.

[0116] Aspect 22. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 5 wt.% or greater of the composition, based on total solid weight of the composition.

[0117] Aspect 23. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 10 wt.% or greater of the composition, based on total solid weight of the composition.

[0118] Aspect 24. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 25 wt.% or lower of the composition, based on total solid weight of the composition.

[0119] Aspect 25. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 20 wt.% or lower of the composition, based on total solid weight of the composition.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0120] Aspect 26. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 15 wt.% or lower of the composition, based on total solid weight of the composition.

[0121] Aspect 27. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 5 to 25 wt.% of the composition, based on total solid weight of the composition.

[0122] Aspect 28. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 5 to 15 wt.% of the composition, based on total solid weight of the composition.

[0123] Aspect 29. The protective coating composition of any preceding aspect, wherein the basalt flake component comprises 10 to 20 wt.% of the composition, based on total solid weight of the composition.

[0124] Aspect 30. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of greater than 10.

[0125] Aspect 31. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of 15 or greater.

[0126] Aspect 32. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of 20 or greater.

[0127] Aspect 33. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of less than 100.

[0128] Aspect 34. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of 50 or less.

[0129] Aspect 35. The protective coating composition of any preceding aspect, wherein the basalt flake in the basalt flake component has an aspect ratio of 30 or less.

[0130] Aspect 36. The protective coating composition of any preceding aspect, wherein the wherein the basalt flake in the basalt flake component has an aspect ratio of greater than 10 to less than 100.

[0131] Aspect 37. The protective coating composition of any preceding aspect, wherein the wherein the basalt flake in the basalt flake component has an aspect ratio of 15 to 50.

[0132] Aspect 38. The protective coating composition of any preceding aspect, wherein the wherein the basalt flake in the basalt flake component has an aspect ratio of 20 to 30.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0133] Aspect 39. The protective coating composition of any preceding aspect, further comprising a phyllosilicate.

[0134] Aspect 40. The protective coating composition of aspect 39, wherein the phyllosilicate comprises a plate-like phyllosilicate.

[0135] Aspect 41. The protective coating composition of aspect 40, wherein the phyllosilicate comprises mica.

[0136] Aspect 42. The protective coating composition of any preceding aspect, further comprising a silica source.

[0137] Aspect 43. The protective coating composition of any preceding aspect, wherein the composition comprises a silica source present in the coating composition in an amount of 0.1 to 5 wt.%, with wt.% based on the total solid weight of the composition.

[0138] Aspect 44. The protective coating composition of any preceding aspect, wherein the composition comprises a silica source present in the coating composition in an amount of 0.4 to 1.0 wt.%, with wt.% based on the total solid weight of the composition.

[0139] Aspect 45. The protective coating composition of any preceding aspect, wherein the composition comprises a silica source comprising silica powder.

[0140] Aspect 46. The protective coating composition of any preceding aspect, wherein the composition comprises a silica source comprising fumed silica.

[0141] Aspect 47. The protective coating composition of any preceding aspect, wherein the composition further comprises a borate source.

[0142] Aspect 48. The protective coating composition of any preceding aspect, wherein the composition further comprises a phosphate source.

[0143] Aspect 49. The protective coating composition of any preceding aspect, wherein the composition further comprises ammonium polyphosphate.

[0144] Aspect 50. The protective coating of aspect 48 or 49, wherein the phosphate is present in the coating composition in an amount of 20 to 35 wt.%, with wt.% based on the total solid weight of the composition.

[0145] Aspect 51. The protective coating composition of any preceding aspect, wherein the composition further comprises an acid source.

[0146] Aspect 52. The protective coating composition of any preceding aspect, wherein the composition further comprises a zinc source.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0147] Aspect 53. The protective coating composition of any preceding aspect, wherein the composition further comprises TiCh.

[0148] Aspect 54. The protective coating composition of any preceding aspect, wherein the composition further comprises a fire-retardant material.

[0149] Aspect 55. The protective coating composition of any preceding aspect, wherein the composition further comprises metal oxide, other than TiCh.

[0150] Aspect 56. The protective coating composition of any preceding aspect, wherein the composition further comprises hydrated metal oxide.

[0151] Aspect 57. The protective coating composition of any preceding aspect, wherein the composition further comprises ATH.

[0152] Aspect 58. The protective coating composition of any preceding aspect, wherein the composition further comprises a reinforcing filler.

[0153] Aspect 59. The protective coating composition of any preceding aspect, wherein the composition further comprises glass microspheres.

[0154] Aspect 60. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of melamine.

[0155] Aspect 61. The protective coating composition of any of aspects 1 to 52 and 54 to 60, wherein the composition is substantially free, essentially free, and / or completely free of TiO2.

[0156] Aspect 62. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a gas source.

[0157] Aspect 63. The protective coating composition of any preceding aspect except aspect 47, wherein the composition is substantially free, essentially free, and / or completely free of a borate source.

[0158] Aspect 64. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of alkyl phosphorous acid(s).

[0159] Aspect 65. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of ethylenically unsaturated monomer residues.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0160] Aspect 66. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a surfactant.

[0161] Aspect 67. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of a non-ionic surfactant.

[0162] Aspect 68. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of silicate.

[0163] Aspect 69. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of layered silicates and / or metallic silicates.

[0164] Aspect 70. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of piperazine salt(s).

[0165] Aspect 71. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of reinforcing fillers.

[0166] Aspect 72. The protective coating composition of any preceding aspect, wherein the composition is substantially free, essentially free, and / or completely free of solvent.

[0167] Aspect 73. A coating layer deposited from the protective coating composition of any preceding aspect.

[0168] Aspect 74. The coating layer of aspect 73, wherein the layer passes the Flame Test.

[0169] Aspect 75. The coating layer of aspect 74, wherein the char produced by the Flame Test has a greater char strength than a similar coating layer deposited from a coating composition lacking a basalt flake component.

[0170] Aspect 76. The coating layer of any of aspects 73 to 75, wherein the coating layer is intumescent.

[0171] Aspect 77. The coating layer of any of aspects 73 to 75, wherein the coating layer is non-intumescent.

[0172] Aspect 78. A self-supported film and / or sheet formed from the protective coating composition of any of aspects 1 to 72.PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0173] Aspect 79. The self-supported film and / or sheet of aspect 78, wherein the film / sheet comprises a mesh.

[0174] Aspect 80. The self-supported film and / or sheet of aspect 78 or 79, wherein the film / sheet comprises an adhesive layer on a surface of the film / sheet.

[0175] Aspect 81. A method for using the coating composition of any of aspects 1 to 72 and / or the film and / or sheet of aspects 78 to 80 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.

[0176] Aspect 82. The method of aspect 81, wherein both the protective coating composition and the film and / or sheet is applied to a substrate.

[0177] Aspect 83. A substrate prepared according to aspect 81 or 82.

[0178] Aspect 84. The substrate of aspect 83, wherein the substrate comprises a vehicle.

[0179] Aspect 85. The substrate of aspect 83, wherein the substrate comprises a battery.

[0180] Aspect 86. A vehicle comprising an ecoat layer and the battery of aspect 85, wherein the ecoat layer is between a surface of the vehicle and the battery.

[0181] Aspect 87. The vehicle of aspect 86, wherein the ecoat layer comprises a fire-resistant ecoat.

[0182] Aspect 88. The vehicle of aspect 86 or 87, wherein the cured coating layer, film and / or sheet is on a surface of the battery.

[0183] Aspect 89. The vehicle of any of aspects 86 to 88, wherein the cured coating layer, film and / or sheet is on an inside surface of a lid of the battery.

[0184] Aspect 90. The vehicle of any of aspects 86 to 89 wherein the cured coating layer, film and / or sheet is on an inside surface of a box comprising the battery.

[0185] Aspect 91. The vehicle of aspect 84, wherein the coating layer, film, and / or sheet comprises part of a coating stack.

[0186] Aspect 92. The vehicle of any of aspects 84 or 86 to 90, wherein the vehicle further comprises an additional fire-retardant material.

[0187] Aspect 93. The substrate of aspect 83, wherein the substrate comprises a structure.EXAMPLESPCT / US26 / 17627 04 March 2026 (04.03.2026)

[0188] The following examples are intended to illustrate the disclosure and should not be construed as limiting the disclosure in any way.

[0189] Coating formulations, Control 1 and Examples 1-4, were prepared using the ingredients shown below; wt.% is reported based on the weight of both the base (film-forming resin) and the hardener. The base for each coating formulation shown in Table 1 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 hardener for each coating formulation shown in Table 2 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 Table 3 below. The base and hardener were mixed by a mixer or spatula, until the color of the mixture became homogenous and lump-free. The coating compositions were then subjected to the Flame Test. Results are shown in Table 4 below.Table 1 - Base Compositions - Control 1 and Examples 1-4PCT / US26 / 17627 04 March 2026 (04.03.2026)1Westlake Chemical Corporation2Gabriel Performance Products3Nippon Electric Glass4Elementis Specialties5Clariant AG6Anhui Estone Materials Technology7LKAB Minerals Ltd.8Zhongkehuaxing9The Chemours Company LLC10Yantai Huazheng Kexin New Material Co., LTDTable 2 - Hardener Compositions - Control 1 and Examples 1-411Huntsman12Huntsman13KUKDO CHEMICAL14KUSUMOTO CHEMICALS, LTD.15AllnexTable 3 - Weight Mix Ratios of Base: Hardener - Control 1 and Examples 1-4Table 4 - Flame Test Results - Control 1 and Formulations 1-4PCT / US26 / 17627 04 March 2026 (04.03.2026)

[0190] As shown in Table 4, coating compositions comprising a film-forming component and basalt flake, Formulations 1-4, all passed the Flame Test with backside temperatures below 440°C and the coating char remained adhered to the panel. The Control formulation failed the Flame Test and the coating char fell off the test panel. The char strength of Example 1 and the control composition were measured by qualitative comparison using finger pressure and visually assessed; the char from Example 1 had greater char strength than the control char.

[0191] In addition, film impact resistance was measured according to the standard GB / T 1732-2020 for the control coating and Example 1. While the control had a coating film impact resistance of 35kg / cm, Example 1 had a coating film impact resistance of 50kg / cm.

[0192] 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 protective coating composition, comprising:a) a film forming component; andb) a basalt flake component.

2. The coating composition of claim 1, wherein the basalt flake component is present in an amount of 5 to 25 wt.%, with wt.% based on the total solid weight of the composition.

3. The coating composition of claim 1 or 2, wherein the basalt flake in the basalt flake component has a D50 particle size of 50 to 75 microns as determined using dynamic light scattering.

4. The coating composition of any preceding claim, wherein the basalt flake in the basalt flake component has an aspect ratio of greater than 10 to less than 100, 15 or greater to 50 or less, and / or 20 or greater to 30 or less.

5. The coating composition of claim 4, wherein the basalt flake in the basalt flake component has an aspect ratio of 23 + / - 3.

6. The coating composition of any preceding claim, further comprising one or more of a fire-retardant material, a borate source, a silica source, a zinc source, an acid source, phyllosilicate, a phosphate source, and / or TiCh.

7. The coating composition of any preceding claim, in which the film-forming component comprises an epoxy resin and polyamine crosslinker.

8. 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 gas source, a borate source, alkyl phosphorus acid(s), a melamine, ethylenically unsaturated monomer residues, a surfactant, silicate(s), piperazine salt(s), a reinforcing filler, TiCh and / or a solvent.

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

10. A method for using the coating composition and / or film and / or sheet of any of claims 1 to 9 to coat at least a portion of a surface of 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.

11. A substrate coated according to the method of claim 10.

12. An article comprising the substrate of claim 11.

13. The article of claim 12, wherein the article comprises a battery.

14. The battery of claim 13, wherein the battery comprises exterior wall elements defining a housing and optionally interior wall elements, wherein the coating composition, film and / 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, and wherein any of the exterior wall and / or interior wall elements comprises composite, steel, aluminum, and / or polycarbonate.

15. The battery of claim 13 or 14, further comprising one or more fire-retardant materials and / or fire mitigation means inside and / or outside the battery, including a thermally insulating material, fiberglass, mineral wool, silica / silica fibers, alumina, Kevlar, Nomex, calcium-silicate, calcium silicate fibers, polyurethane / polyurea foam, cooling fins, mica boards, Aerogel blankets, and / or mineral / glass / carbon fiber-containing blankets.

16. A vehicle housing the battery of any of claims 13 to 15.

17. The vehicle of claim 16, wherein the vehicle has a surface coated at least in part with a fire-resistant ecoat.

18. A vehicle comprising the substrate of claim 11.

19. The vehicle of claim 18 further comprising an electric battery, wherein the coated substrate is between the vehicle frame and the battery.

20. A structure comprising the substrate of claim 11.

Images