Non or low-intumescent fire-resistant coatings and coating compositions

Patent metadata

Field	Value
Publication number	US-2026078266-A1
Application number	US-202519302985-A
Country	US
Kind code	A1
Filing date	Aug 18, 2025
Priority date	Sep 13, 2024
Publication date	Mar 19, 2026
Grant date	—

Abstract

Non or low-intumescent fire-resistant coatings, coating compositions used to form the coatings, and composite articles including the coatings are provided herein. In an embodiment, a non or low-intumescent fire-resistant coating is formed from an aqueous coating composition comprising a polyurethane urea resin, a melamine crosslinker, a silicone resin, and a filler. The non or low-intumescent fire-resistant coating has a thermal conductivity of from about 0.03 W/m-K to about 0.1 W/m-K, as measured using a guarded hot plate apparatus in accordance with ASTM E1530. The coating expands by from about 0.1% to about 10% based on a total volume of the coating, after exposure to a propane flame at a distance of 26 mm from the coating and/or exposure to a temperature of about 1200° C. for a period of at least 10 minutes.

First claim

What is claimed is:

1 . A non or low-intumescent fire-resistant coating formed from an aqueous coating composition comprising:
a polyurethane urea resin; a melamine crosslinker; a silicone resin; and a filler;
wherein the non or low-intumescent fire-resistant coating has a thermal conductivity of from about 0.03 W/m-K to about 0.1 W/m-K, as measured using a guarded hot plate apparatus in accordance with ASTM E1530;
wherein the non or low-intumescent fire-resistant coating expands by from about 0.1% to about 10%, based on a total volume of the coating, when exposed to a propane flame at a distance of 26 mm from the coating and/or when exposed to a temperature of about 1200° C. for a period of at least 10 minutes.

2 . The non or low-intumescent fire-resistant coating of claim 1 , having a dielectric breakdown voltage, as measured using the Short-Time Test (Method A) in accordance with ASTM D149-20, of from about 6 kV to about 15 kV before exposure to fire, and from about 2.5 kV to about 15 kV after exposure to a propane flame at a distance of 26 mm from the coating and/or exposure to a temperature of about 1200° C. for a period of at least 10 minutes.

3 . The non or low-intumescent fire-resistant coating of claim 1 , wherein the filler comprises a porous glass aggregate.

4 . The non or low-intumescent fire-resistant coating of claim 1 , wherein the filler comprises silicon dioxide.

5 . The non or low-intumescent fire-resistant coating of claim 3 , wherein the filler further comprises a mineral fiber.

6 . The non or low-intumescent fire-resistant coating of claim 1 , wherein the aqueous coating composition further comprises a surfactant.

7 . A composite article comprising:
a substrate; and the non or low-intumescent fire-resistant coating of claim 1 , bonded to the substrate.

8 . The composite article of claim 7 , wherein the coating has a thickness of from about 0.5 mm to about 3.0 mm.

9 . The composite article of claim 7 , further comprising an additional layer disposed between the substrate and the coating.

10 . The composite article of claim 7 , wherein the composite article is a battery housing.

11 . The composite article of claim 7 , wherein, when the non or low-intumescent fire-resistant coating has a thickness of about 2 mm and when a temperature of the substrate is about 25° C. before exposure to heat or flame, the temperature of the substrate increases to no more than about 400° C., as measured using a thermocouple in direct contact with the substrate on a side of the substrate opposite the coating, when exposed to a propane flame at a distance of 26 mm from the coating and/or when exposed to a temperature of about 1200° C. for a period of at least 10 minutes.

12 . The composite article of claim 7 , wherein the coating demonstrates no cracking, as determined by visual observation at a distance of 3 feet from the composite article in a room with standard lighting, when the composite article is folded at 90 degrees, both before and after exposure to a propane flame at a distance of 26 mm from the coating and/or exposure to a temperature of about 1200° C. for a period of at least 10 minutes.

13 . An aqueous coating composition comprising:
a polyurethane urea resin; a melamine crosslinker; a silicone resin; and a filler, comprising:
a porous glass aggregate; and
a non-glass filler.

14 . The aqueous coating composition of claim 13 , having a Krebs viscosity of from about 120 Krebs units to about 240 Krebs units, as measured in accordance with ASTM D562-10 using a Krebs Stormer type viscometer with a paddle spindle rotating at 200 RPM at a temperature of 25° C.

15 . A method of forming a composite article, comprising:
applying the coating composition of claim 13 to a substrate to form a film; and curing the film.

16 . The method of claim 15 , wherein applying the coating composition comprises spraying the coating composition using gravity fed spray equipment and/or pressure fed spray equipment.

17 . The aqueous coating composition of claim 13 , wherein the silicone resin is present in the aqueous coating composition in an amount of from about 20 wt % to about 35 wt %, based on a total weight of the aqueous coating composition.

18 . The aqueous coating composition of claim 13 , wherein the weight ratio of the porous glass aggregate to the non-glass filler is from about 2:1 to about 10:1.

19 . The aqueous coating composition of claim 13 , wherein the porous glass aggregate has a D50 nominal particle dimension of from about 0.3 mm to about 1.2 mm, as measured using a sieve in accordance with ASTM 5861-07 (2017).

20 . The aqueous coating composition of claim 18 , wherein:
the filler comprises a mineral fiber in an amount of from about 3 wt % to about 7 wt %, based on a total weight of the coating composition; the silicone resin is present in the aqueous coating composition in an amount of from about 20 wt % to about 35 wt %, based on a total weight of the aqueous coating composition; the weight ratio of the silicone resin to the polyurethane urea resin is from about 1:3 to about 3:1; and the porous glass aggregate has a D50 nominal particle dimension of from about 0.3 mm to about 1.2 mm, as measured by as measured using a sieve in accordance with ASTM 5861-07 (2017).

Assignees

• Axalta Coating Systems Ip Co

Inventors

• Istivan Stephen
• Bhargava Gaurang
• Trindade Delson J
• Sullivan Ian

Classifications

• C08K2201/005

  Additives being defined by their particle size in general · CPC title

• C08K3/36

  Silica · CPC title

• C08K7/10

  Silicon-containing compounds · CPC title

• C08K7/28

  Glass · CPC title

• C08G18/40

  High-molecular-weight compounds {(C08G18/2805 takes precedence)} · CPC title