Search

EP-4739741-A1 - NON-INTUMESCENT, PROTECTIVE COATINGS

EP4739741A1EP 4739741 A1EP4739741 A1EP 4739741A1EP-4739741-A1

Abstract

Non-intumescent coating compositions having a water generating material are disclosed, as are methods for using such compositions and substrates coated with same.

Inventors

  • MA, SHUANG
  • TADIMOELJO, Isaiah Daniël Ronald

Assignees

  • PPG Industries Ohio Inc.

Dates

Publication Date
20260513
Application Date
20240702

Claims (20)

  1. 1. A coating composition comprising: a) a film forming component; and b) a water-generating material in an amount of 45 wt.% or greater based on total solids of the coating, wherein the coating is non-intumescent.
  2. 2. The coating composition of Claim 1, wherein the water generating material is present in an amount of 45 to 70 wt.%, where wt.% is based on total solid weight of the composition.
  3. 3. The coating composition of any preceding claim, further comprising a borate source, a silica source, a zinc source, an acid source, a metal oxide that is not a water-generating material, titanium isopropoxide, a carbon source, inorganic fillers, glass fibers and/or mineral fibers, rheology additives, organic solvents, pigments, foam stabilizers, or combinations thereof.
  4. 4. The coating composition of Claim 3, comprising one or more of these additives in a total amount of 2-20 wt. %, where wt.% is based on the total solid weight of the composition.
  5. 5. The coating composition of any preceding claim in which the film- forming component comprises an epoxy resin and amine crosslinker, and the water-generating material comprises a hydrated metal oxide.
  6. 6. The composition of any preceding claim, wherein the composition is substantially free, essentially free, and/or completely free of one or more of the following: a borate source, alkyl phosphorus acid(s), a melamine or melamine derivative, residues of ethylenically unsaturated monomer such as those from (meth)acrylic and/or styrene, a surfactant including, but not limited to, a non-ionic surfactant, silicates including, but not limited to, layered silicate, and aluminum silicate(s), piperazine salt(s), a reinforcing filler, such as fibers, and/or a solvent.
  7. 7. A self- supported film or sheet formed from the coating composition of any preceding claim.
  8. 8. The coating or self-supported film or sheet of Claims 1-7 where the coating/film/shcct is a protective coating as determined according to the Thermal Runaway Test.
  9. 9. A method for using the coating composition or the film or sheet of Claims 1-8 to coat a substrate comprising applying to at least a portion of the substrate, the coating composition, film, or sheet.
  10. 10. The method of Claim 9, wherein the substrate comprises metal, such as aluminum or steel, and/or plastic, such as polycarbonate, and/or composite.
  11. 11. A substrate coated according to the method of any of Claims 9 or 10.
  12. 12. An article comprising the substrate of Claim 11.
  13. 13. The article of Claim 12, wherein the article comprises an energy storage device such as a battery, such as a lithium-ion battery.
  14. 14. The article of Claim 13, wherein the battery comprises exterior wall elements defining a housing and optionally interior wall elements, wherein the coating composition or 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.
  15. 15. The article of Claims 13-14, further comprising one or more fire-retardant materials and/or fire mitigation means inside and/or outside the battery, such as a thermally insulating material; a reinforcing material, such as fiberglass, mineral wool, silica/silica fibers, alumina, Kevlar, Nomex, calcium- silicate, or calcium silicate fibers; foam, such as poly urethane/poly urea foam with fire retardants; and/or physical barriers, such as cooling fins, mica boards, Aerogel blankets, and/or mineral/glass/carbon fiber-containing blankets.
  16. 16. The article of Claim 12, wherein the article comprises a vehicle.
  17. 17. The article of Claim 16, wherein the vehicle has a surface coated at least in part with a fire-resistant ecoat and/or a flame-retardant adhesive.
  18. 18. The article of Claim 17, wherein the fire-resistant ecoat comprises an inorganic, plate-like pigment and a P:B ratio of 0.4: 1 or higher.
  19. 19. The article of Claim 12, wherein the article comprises a structure.
  20. 20. A vehicle comprising a surface coated, at least in part, with the composition, sheet or film of any of Claims 1-8, and an electric battery, wherein the composition, sheet or film is between the surface and the battery.

Description

NON-INTUMESCENT, PROTECTIVE COATINGS FIELD [0001] The present disclosure is directed to a non-intumescent, protective coating composition, to a method for using such composition to coat a substrate, to a substrate coated with said composition, and to an article comprising said substrate. BACKGROUND [0002] Protective coatings, such as fire-retardant 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 used for energy storage devices, are therefore desired. SUMMARY [0003] The present disclosure is directed to a coating composition comprising a) a filmforming component; and b) a water-generating material in an amount of 45 wt.% or greater based on total solids of the coating, wherein the coating is non-intumescent. [0004] The compositions can be formed into a self-supporting film or sheet. Methods of using the coating composition and/or film or sheet to coat substrates, and substrates coated thereby, as well as articles comprising such coated substrates are also within the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWING [0005] FIG. 1 is a schematic of the Thermal Runaway Test. DETAILED DESCRIPTION [0006] The present disclosure is directed to a coating composition comprising a) a filmforming component; and b) a water-generating material in an amount of 45 wt.% or greater based on total solids of the coating, wherein the coating is non-intumescent. [0007] The present coating composition can be used to form non-intumescent, protective coatings. “Protective coating” and like terms as used herein refer to a coating that passes the following test, shown in Figure 1 : the coating is applied to one side of a first steel panel 2 that is 0.6 to 1.2 mm thick and the coating is then cured to a dry film thickness of 2000 microns +/- 100 microns; a second steel panel 4, which may have the same thickness as the first steel panel 2, is placed on top of the cured coating 6 and the “sandwich” held together such that there are no gaps between the cured coating 6 and the two steel panels 2,4. The uncoated side 10 of the first steel panel 2 is exposed to 1450 ± 50°C at a thermal output of >5 kW; if, after five minutes exposure to the flame 8, the uncoated side 12 of the second steel panel 4 is at a temperature of 250°C or lower, such as when measured with a thermal couple 14, the coating is a protective coating within the scope of the present disclosure. Maintaining the uncoated surface of the second panel below this temperature demonstrates the thermally insulating properties of a coating. This test is intended to mimic a thermal runaway event in a battery and is therefore referred to herein as the “Thermal Runaway Test”. “Thermally insulating” and like terms refer to minimization of heat transfer between materials. [0008] Coatings deposited from the present coating composition are non-intumescent. “Non-intumescent” and like terms, when used in reference to the present coatings, means that the coatings undergo expansion of no more than 5 times their dry film thickness upon exposure to 1450 ± 50°C at a thermal output of >5, such as below 3 times expansion, or below 1 time expansion. This expansion is significantly less than other coatings proposed for use with battery components, which may expand by 20 times or more of their dry film thickness. It is therefore a feature of the present disclosure to provide a composition with minimal expansion while still providing protection against fire. [0009] The coating compositions according to the present disclosure are particularly suitable for the surfaces of energy storage devices, especially the inside surfaces of such devices. If applied to a battery used in an electric vehicle, the present coatings (or sheets/films made from the same) may contain excessive heat and/or fire within the battery and keep the heat/fire from spreading to other parts of the vehicle. The present coatings may retard, if not prevent, flammable materials in the car from catching fire. The thermal insulation of the present coatings may also mitigate heat damage outside of the energy storage device, such as damage to other parts of a vehicle or structure, and/or may mitigate the chance of igniting elements outs