[go: up one dir, main page]

WO2025183770A1 - Compositions contenant des composés fonctionnels furane et fonctionnels isocyanate et matériau expansible - Google Patents

Compositions contenant des composés fonctionnels furane et fonctionnels isocyanate et matériau expansible

Info

Publication number
WO2025183770A1
WO2025183770A1 PCT/US2024/058198 US2024058198W WO2025183770A1 WO 2025183770 A1 WO2025183770 A1 WO 2025183770A1 US 2024058198 W US2024058198 W US 2024058198W WO 2025183770 A1 WO2025183770 A1 WO 2025183770A1
Authority
WO
WIPO (PCT)
Prior art keywords
composition
substrate
weight
coating
filler
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/058198
Other languages
English (en)
Inventor
Joseph Peter KRILEY
Paul Takunda CHAZOVACHII
Daniel Philip JAHANIAN
Cristian Antonio MORALES RIVERA
Michael Ryan MARTINEZ
Brendan Joseph GRAZIANO
Patrick Kernell KEANE
Steven Edward BOWLES
Hongying Zhou
David Joseph FORTMAN
JR. Marvin Michael POLLUM
Amy Liane Toolis
Ingrid Rose ZIMMERMAN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
PPG Industries Ohio Inc
Original Assignee
PPG Industries Ohio Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by PPG Industries Ohio Inc filed Critical PPG Industries Ohio Inc
Publication of WO2025183770A1 publication Critical patent/WO2025183770A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/003—Polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/16—Catalysts
    • C08G18/22—Catalysts containing metal compounds
    • C08G18/24—Catalysts containing metal compounds of tin
    • C08G18/244—Catalysts containing metal compounds of tin tin salts of carboxylic acids
    • C08G18/246—Catalysts containing metal compounds of tin tin salts of carboxylic acids containing also tin-carbon bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/2805—Compounds having only one group containing active hydrogen
    • C08G18/2815—Monohydroxy compounds
    • C08G18/282—Alkanols, cycloalkanols or arylalkanols including terpenealcohols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/73—Polyisocyanates or polyisothiocyanates acyclic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78—Nitrogen
    • C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
    • C08G18/791—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
    • C08G18/792—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/80—Masked polyisocyanates
    • C08G18/8061—Masked polyisocyanates masked with compounds having only one group containing active hydrogen
    • C08G18/8064—Masked polyisocyanates masked with compounds having only one group containing active hydrogen with monohydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/04—Polyurethanes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/242—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries against vibrations, collision impact or swelling
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C08K2003/265—Calcium, strontium or barium carbonate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • Coating compositions including sealants and adhesives, are utilized in a wide variety of applications to treat a variety of substrates or to bond together two or more substrate materials.
  • compositions comprising: a first component comprising a first compound comprising a furan functional group and an isocyanate functional group; a second component comprising a dienophile-containing compound; and a thermally expandable material.
  • Also disclosed herein are methods of coating a substrate comprising contacting a portion of a surface of the substrate with any of the compositions disclosed herein.
  • substrates comprising a thermally expandable coating formed from any of the compositions disclosed herein on a portion of a surface of the substrate.
  • batteries comprising any of the battery cells disclosed herein.
  • FIG. 1 is a schematic of a top-down view of cylindrical battery cells.
  • FIG. 2 is a schematic of an exploded isometric view of an array of prismatic battery cells.
  • FIG. 3 is a schematic of a front view of an array of pouch battery cells.
  • FIG. 4 is a schematic of an isometric view of cylindrical cells positioned in a battery module.
  • FIG. 5 is a schematic of an exploded perspective view of a battery pack comprising multiple battery cells.
  • FIG. 6 is a schematic of an isometric view of (A) a battery cell, (B) a battery module, and (C) a battery pack.
  • FIG. 7 is a schematic of a perspective view of a battery pack.
  • FIG. 8 is a schematic of a cell to battery pack configuration.
  • FIG. 9 is a schematic of an isometric cut-out view of a cell to chassis battery assembly.
  • any numerical range recited herein is intended to include all sub-ranges subsumed therein.
  • a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
  • the terms “on,” “onto,” “applied on,” “applied onto,” “formed on,” “deposited on,” “deposited onto,” and the like mean formed, overlaid, deposited, or provided on, but not necessarily in contact with, a substrate surface.
  • a composition “applied onto” a substrate surface does not preclude the presence of one or more other intervening coatings of the same or different composition located between the composition and the substrate surface.
  • a “solid” means a material having a viscosity of at least 100,000 Pa*s at 25°C as measured by parallel plate rheology with a plate diameter of 25 mm, a gap of 0.5 mm, and a shear rate of 1 s’ 1 .
  • moiety refers to a part of the chemical structure of a molecule or compound that may include a substructure, such as a functional group or a linkage.
  • coating refers to a coating composition applied to a substrate and cured.
  • an “article” refers to the cured composition as a formed or fabricated solid.
  • a “sealant composition” refers to a coating composition that forms a sealant in its cured state.
  • a “sealant” refers to a coating or a free-standing film that can provide a protective barrier against moisture, chemicals, and other environmental factors, preventing corrosion and extending the lifespan of components.
  • an “adhesive composition” refers to a coating composition that forms an adhesive in its cured state.
  • an “adhesive” refers to a cured coating or a free-standing film that forms a load-bearing joint having a lap shear strength of at least 0.5 MPa and less than 5 MPa, as determined according to ASTM D 1002- 10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute at room temperature.
  • a “structural adhesive composition” refers to a coating composition that, in a cured state, produces a structural adhesive.
  • a “structural adhesive” refers to a cured coating or a freestanding film that forms a load bearing joint having a lap shear strength of at least 5 MPa measured according to ASTM D 1002- 10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute at room temperature.
  • ambient conditions generally refer to room temperature (e.g., 25°C) and humidity conditions or temperature and humidity conditions that are typically found in the area in which the composition is applied to a substrate, e.g., at 10°C to 40°C and 5% to 80% relative humidity, while “slightly thermal conditions” are temperatures that are slightly above ambient conditions, such as greater than 40°C to 60°C.
  • two-component refers to a composition in which the reactive components readily associate to form an interaction or react to form a bond (physically or chemically), i.e., cure, without activation from an external energy source, such as at ambient or slightly thermal conditions, when mixed.
  • an external energy source such as at ambient or slightly thermal conditions
  • hot melt refers to a composition that (i) cures under ambient conditions to form a solid, (ii) begins to reflow upon exposure to the reflow onset temperature to form a liquid, (iii) begins to reform a solid upon cooling below the reflow onset temperature, and (iv) reforms a solid at ambient conditions.
  • the term “reflow onset temperature” means the temperature at which the storage modulus of the composition drops below 20,000,000 Pa as may be determined by performing Dynamic Mechanical Analysis (DMA) at a frequency of 1.0 Hz and a temperature ramp rate of 3°C/min.
  • the reflow onset temperature may be the result of dynamic covalent chemistry, softening (i.e., heating beyond the glass transition temperature of the composition), and/or melting (i.e., converting from a solid to a liquid).
  • the term “glass transition temperature” (“Tg”) refers to the temperature at which an amorphous material, such as glass or a polymer, changes from a brittle vitreous state to a plastic state or from a plastic state to a brittle vitreous state.
  • the term “hot melt application” means application of a hot melt to a substrate surface under thermal conditions.
  • thermal conditions include (i) heat extrusion, (ii) heating the composition to a temperature greater than the reflow onset temperature of the composition, and/or (iii) heating of the substrate comprising the composition to a temperature greater than the reflow onset temperature of the composition.
  • the term “cohesive,” when used with respect to a coating, means the expanded coating (a coating that has been exposed to at least the expansion onset temperature of the thermally expanded material) is held together as part of a single mass, i.e., the expanded coating does not crumble.
  • non-cohesive when used with respect to a coating, means the expanded coating (a coating that has been exposed to at least the expansion onset temperature of the thermally expanded material) is not held together as pail of the same mass, i.e., the expanded coating crumbles.
  • cur means that the reactive components that form the composition interact, react, and/or are crosslinked to form a coating, a free-standing film, or a bond.
  • the composition begins to cure when the components of the composition are mixed, resulting in the reaction and/or physical interaction of the reactive components of the composition.
  • curing of a composition refers to subjecting the composition to curing conditions that result in cure of the composition.
  • a “curable” composition refers to a composition that may be cured.
  • a curable composition may be considered “cured” if it has a lap shear strength of at least 0.5 MPa (measured according to ASTM D 1002- 10) and a tensile strength of at least 0.5 MPa at ambient conditions (measured according to ISO-37 TYPE 2 using an Instron 4443 machine in tensile mode with a pull rate of 10 mm per minutes). “Complete” cure is obtained when a curable composition is subjected to curing conditions without any significant increase in lap shear strength.
  • furan equivalent weight is the theoretical molecular weight of a compound comprising a furan functional group divided by the theoretical number of furan functional groups.
  • isocyanate equivalent weight is the theoretical molecular weight of a compound comprising an isocyanate functional group divided by the theoretical number of isocyanate functional groups.
  • maleimide equivalent weight is the theoretical molecular weight of a compound comprising a maleimide functional group divided by the theoretical number of maleimide functional groups.
  • an accelerator means a substance that increases the rate or decreases the activation energy of a chemical reaction in comparison to the same reaction in the absence of the accelerator.
  • An accelerator may be either a “catalyst” (that is, without itself undergoing any permanent chemical change) or may be reactive (that is, undergoing a permanent chemical change).
  • a “latent” accelerator refers to a molecule or a compound that is activated by an external energy source prior to reacting (i.e., crosslinking) or having a catalytic effect, as the case may be.
  • the latent accelerator may be in the form of a solid at room temperature and has no accelerator effect until it is heated and melts.
  • the latent accelerator may be blocked or encapsulated.
  • a “blocked” accelerator means an accelerator that may be reversibly reacted with a second compound that prevents any accelerator effect until the reversible reaction is reversed by the application of heat and the second compound is removed, freeing the accelerator to increase the rate or decrease the activation energy of a chemical reaction.
  • an “encapsulated” accelerator may be encapsulated within a thermoplastic material which melts upon heating, releasing the accelerator to increase the rate or decrease the activation energy of chemical reactions.
  • urethane linkage means a bond formed between two molecules forming the linkage RNHC(O)OR.
  • urea linkage means a bond formed between two molecules forming the linkage RNHC(O)NHR.
  • thiourethane linkage means a bond formed between molecules forming the linkage RNHC(O)SR.
  • reprocessability means that the composition is capable of undergoing reprocessing, wherein an article comprising the cured composition is mechanically or chemically processed into a different article.
  • “reprocessing” may refer to a mechanical process wherein an article comprising the cured composition is ground, chopped, pulverized, or processed by a mechanical means, then the composition is molded into a new article via a process such as compression molding, extrusion, or the like (i.e., the material is recycled). The reprocessing may further comprise heating.
  • Reprocessing efficiency means the ratio of a mechanical property of the material after reprocessing relative to the mechanical property of the original material, typically defined as a percentage. Reprocessing efficiency may refer to the efficiency of recovery of properties such as tensile strength, Young’s modulus, strain at break, lap shear strength, or the like, following reprocessing.
  • reshaping means a material that was previously molded into a fixed physical form or shape is capable of being molded into a different fixed physical form or shape. In some cases, reshaping will involve heating the material to above a reflow onset temperature of the material to make the new shape permanent.
  • self-healing means that a material is capable of repairing itself, for example, healing cracks, scratches, or marring in the material.
  • the self-healing process may comprise heating the material above the material’s reflow onset temperature.
  • “monosubstituted” refers to a compound or functional group in which one hydrogen is substituted by a different atom or functional group.
  • terminal when used with respect to a functional group, refers to a functional group that is at the end of a polymer backbone or a prepolymer backbone or monosubstituted with respect to a monomer or non-polymerizable molecule.
  • monomer refers to a molecule which can undergo polymerization, thereby contributing repeat units to the structure of a prepolymer or a polymer, as defined in Pure and Applied Chemistry, 1996, 68, 2287 (2289), “Glossary of basic terms in polymer science (IUPAC Recommendations 1996).”
  • prepolymer refers to a molecule comprising a reaction product of two or more molecules that can be further polymerized or crosslinked.
  • polymer refers to a molecule having more than one repeating unit and includes oligomers and homopolymers.
  • the term “substantially free” means that a particular material is not purposefully added to a mixture or composition, respectively, and is present only as an impurity in a trace amount of less than 0.05% by weight based on a total weight of the mixture or composition, respectively.
  • the term “essentially free” means that a particular material is present only in an amount of less than 0.01% by weight based on a total weight of the mixture or composition, respectively.
  • the term “completely free” means that a mixture or composition, respectively, does not comprise a particular material, i.e., the mixture or composition comprises 0% by weight of such material.
  • non-thermally conductive filler or “NTC filler” means a pigment, filler, or inorganic powder that has a thermal conductivity of less than 5 W/m K at 25°C (measured according to ASTM D7984).
  • the term “electrically insulative filler” or “El filler” means a pigment, filler, or inorganic powder that has a volume resistivity of at least 1 Q-m (measured according to ASTM D257).
  • electrically conductive filler or “EC filler” means a pigment, filler, or inorganic powder that has a volume resistivity of less than 1 Q-m (measured according to ASTM D257).
  • thermally expandable means a pigment, filler, encapsulant, thermoplastic, inorganic powder, capsule, microcapsule, or the like that, upon heating, undergoes an increase in volume in at least one dimension.
  • expansion temperature means the temperature at which a thermally expandable material begins to undergo an increase in volume in at least one dimension, i.e., the temperature at which the thermally expandable material begins to expand.
  • the present disclosure is directed to a composition
  • a composition comprising, consisting essentially of, or consisting of: a first component comprising a first compound comprising a furan functional group and an isocyanate functional group; a second component comprising a dienophile-containing compound; a thermally expandable material; and a thermally conductive filler.
  • the first component may comprise, consist essentially of, or consist of a first compound comprising a furan functional group and an isocyanate functional group.
  • the first compound may further comprise a urethane linkage, a urea linkage, and/or a thiourethane linkage.
  • the first compound may comprise the general structure: wherein X comprises O, N, or S; m > 1; n > 1; the sum of m+n > 2; Ri comprises a substituted or unsubstituted alkyl group, an alkylene group, a (cyclo)alkyl group, an aromatic group, an isocyanurate moiety, a biuret moiety, an allophonate moiety, a glycoluril moiety, a benzoguanamine moiety, an iminooxadiazinedione moiety, or a polymeric moiety different from the urethane linkage, the urea linkage, and/or a thiourethane linkage; and R2 comprises a substituted or unsubstituted alkyl group, an ester moiety, an ether moiety, or a urethane moiety.
  • the first compound may comprise a reaction product of reactants comprising a furan-containing compound comprising an active hydrogen-containing functional group and a polyisocyanate-containing compound.
  • a furan-containing compound refers to a compound comprising a furan functional group.
  • a “polyisocyanate-containing compound” refers to a compound comprising more than one isocyanate functional groups, including diisocyanatcs, triisocyanatcs, or higher.
  • the active hydrogcn-containing functional group on the furan-containing compound may comprise a hydroxyl functional group, an amine functional group, and/or a thiol functional group.
  • the active hydrogen-containing functional group of the furan-containing compound may react with an isocyanate group of the polyisocyanate.
  • the first compound comprises at least one unreacted isocyanate group, providing the first compound with isocyanate functionality.
  • a sub-stoichiometric amount of the active hydrogen-containing functional group on the furan-containing compound may be reacted with the isocyanate functional groups on the polyisocyanate-containing compound.
  • the active hydrogen-containing functional group of the furan-containing compound and the isocyanate groups on the polyisocyanate-containing compound may be reacted at an equivalence ratio of less than 1:1, such as no more than 1:2, such as no more than 1:3, such as no more than 1:5.
  • sub- stoichiometric means that the number of active hydrogen-containing functional groups from the furan-containing compound is lower than the number required to react with all of the isocyanate groups on the polyisocyanate-containing compound, so that the reaction product comprises isocyanate functionality from the polyisocyanate.
  • Suitable furan-containing compounds useful in forming the first compounds disclosed herein include but are not limited to furfuryl alcohol, furfuryl amine, furfuryl mercaptan, furfuryl glycidyl ether, bis(hydroxymethyl)furan, derivatives thereof, and/or combinations thereof.
  • Suitable polyisocyanate-containing compounds useful in forming the first compounds disclosed herein can be polymeric containing two or more isocyanate functional groups.
  • the polyisocyanates may comprise 2 to 20 carbon atoms and may be linear, cyclic, aliphatic, and/or aromatic polyisocyanates, or mixtures thereof.
  • Suitable aliphatic polyisocyanates may include alkylene isocyanates, such as: trimethylene diisocyanate, tetramethylene diisocyanate, such as 1 ,4-tetramethylene diisocyanate; pentamethylene diisocyanate, such as 1,5 -pentamethylene diisocyanate and 2-methyl-l,5- pentamethylene diisocyanate; hexamethylene diisocyanate (“HDI”), such as 1,6-hexamethylene diisocyanate and 2,2,4- and 2,4,4-trimethylhexamethylene diisocyanate, or mixtures thereof; heptamethylene diisocyanate, such as 1,7-heptamethylene diisocyanate; propylene diisocyanate, such as 1 ,2-propylene diisocyanate; butylene diisocyanate, such as 1 ,2-butylene diisocyanate, 2,3-butylcnc diisocyanatc, and
  • Aliphatic polyisocyanates may also include cycloalkylene isocyanates, such as: cyclopentane diisocyanate, such as 1,3-cyclopentane diisocyanate; cyclohexane diisocyanate, such as 1,4-cyclohexane diisocyanate, 1,2-cyclohexane diisocyanate, isophorone diisocyanate (“IPDI”), IPDI trimer (commercially available as Desmodur® Z 4470 SN); methylene bis(4- cyclohexylisocyanate) (“HMDI”); polymeric methylene diphenyl diisocyanate (“MDI”); and mixed aralkyl diisocyanates such as tetramethylxylyl diisocyanates, such as meta- tetramethylxylylene diisocyanate (commercially available as TMXDI® from Allnex SA).
  • cycloalkylene isocyanates such as
  • Suitable aromatic polyisocyanates may include arylene isocyanates, such as: phenylene diisocyanate, such as m-phenylene diisocyanate, p-phenylene diisocyanate, and chlorophenylene 2,4-diisocyanate; naphthalene diisocyanate, such as 1,5-naphthalene diisocyanate and 1 ,4-naphthalene diisocyanate.
  • arylene isocyanates such as: phenylene diisocyanate, such as m-phenylene diisocyanate, p-phenylene diisocyanate, and chlorophenylene 2,4-diisocyanate; naphthalene diisocyanate, such as 1,5-naphthalene diisocyanate and 1 ,4-naphthalene diisocyanate.
  • Aromatic polyisocyanates may also include alkarylene isocyanates, such as: methylene-interrupted aromatic diisocyanates, such as 4,4’- diphenylene methane diisocyanate (“MDI”), and alkylated analogs such as 3,3’-dimethyl-4,4’- diphenylmethane diisocyanate, and polymeric methylenediphenyl diisocyanate; toluene diisocyanate (“TDI”), such as 2,4-tolylene or 2,6-tolylene diisocyanate, or mixtures thereof, bitoluene diisocyanates; and 4,4-toluidine diisocyanate; xylene diisocyanate; dianisidine diisocyanate; xylylene diisocyanate; and other alkylated benzene diisocyanates.
  • MDI 4,4’- diphenylene methane diisocyanate
  • TDI toluene
  • Suitable polyisocyanates include dimers, trimers, oligomers, or prepolymers comprising any of the isocyanates listed herein.
  • the first compound may comprise, consist essentially of, or consist of a monomer, a prepolymer, or a polymer.
  • the first compound may comprise one, two, three, or more furan functional groups.
  • the furan functional group may be linked to the first compound by a urethane linkage, a urea linkage, and/or a thiourethane linkage.
  • the furan functional group of the first compound may be terminal.
  • the first compound of the present disclosure may be substantially free, essentially free, or completely free of an ether linkage.
  • the first compound may comprise a furan equivalent weight of at least 100 g/eq, such as at least 200 g/eq.
  • the first compound may comprise a furan equivalent weight of no more than 3,000 g/eq, such as no more than 1,500 g/eq.
  • the first compound may comprise a furan equivalent weight of 100 g/eq to 3,000 g/eq, such as 200 g/eq to 1,500 g/eq.
  • the second component may comprise, consist essentially of, or consist of a dienophile-containing compound.
  • a dienophile means any unsaturated functional group capable of undergoing a Diels-Alder [4+2] cycloaddition with a conjugated diene.
  • a “conjugated diene” refers to a compound containing two double bonds separated by a single covalent bond.
  • Suitable dienophiles may comprise a maleimide functional group, a maleate functional group, and/or a fumarate functional group.
  • the dienophile-containing compound may comprise a maleimide functional group.
  • the general structure of the dienophile-containing compound comprising a maleimide functional group comprises: wherein R3 may comprise a hydrogen, an alkyl, a (cyclo)alkyl, an aryl, an aromatic, or a polymeric structure (including a polyester, a polyurethane, a polyether, an acrylic, or a siloxane).
  • Suitable maleimide-containing compounds can be prepared by the reaction of maleic anhydride with di- or polyfunctional amine-containing compounds.
  • the amine- containing compound may be selected such that the maleimide-containing compound or mixture of maleimide-containing compounds does not crystallize.
  • suitable maleimide-containing compounds include the reaction products of maleic anhydride with dimer fatty acid diamines, such as BMI-689, commercially available from Designer Molecules, Inc.
  • Additional maleimide-containing compounds include the reaction products of amine-terminated polyethers or polysiloxanes with maleic anhydride.
  • maleimide-containing compounds include maleimide-terminated poly imides, available from Designer Molecules, Inc., or reaction products of maleimide-functional carboxylic acids with epoxy, hydroxy, or other carboxylic acid-rcactivc functional groups.
  • the dienophile may comprise a maleate functional group.
  • the general structure of the dienophile-containing compound comprising a maleate functional group comprises: wherein each X independently comprises O, N, or S; R4 comprises a hydrogen, an alkyl, a (cyclo)alkyl, an aryl, an aromatic, or a polymeric structure (including a polyester, a polyurethane, a polyether, an acrylic, or a siloxane); and R5 comprises a hydrogen, an alkyl, a (cyclo)alkyl, an aryl, an aromatic, or a polymeric structure (including a polyester, a polyurethane, a polyether, an acrylic, or a siloxane).
  • the dicnophilc-containing compound comprising a maleate functional group may comprise an unsaturated polyester comprising the reaction product of maleic acid (or an anhydride or ester thereof) with a polyol. Suitable polyols include any of those described below.
  • the dienophile-containing compound comprising a maleate functional group may also comprise an unsaturated polyester comprising a maleate functional group synthesized by other methods, such as copolymerization of an epoxide and maleic anhydride.
  • the unsaturated polyester may further comprise other functional groups, such as a hydroxyl group.
  • the unsaturated polyester may comprise a liquid.
  • the dienophile-containing compound may comprise a fumarate functional group.
  • the general structure of the dienophile-containing compound comprising a fumarate functional group comprises: wherein each X independently comprises O, N, or S; Re comprises a hydrogen, an alkyl, a (cyclo)alkyl, an aryl, an aromatic, or a polymeric structure (including a polyester, a polyurethane, a polyether, an acrylic, or a siloxane); and R7 comprises a hydrogen, an alkyl, a (cyclo)alkyl, an aryl, an aromatic, or a polymeric structure (including a polyester, a polyurethane, a polyether, an acrylic, or a siloxane).
  • the dienophile-containing compound comprising a fumarate functional group may comprise an unsaturated polyester comprising the reaction product of fumaric acid (or an anhydride or ester thereof) with a polyol. Suitable polyols include any of those described below.
  • the dienophile-containing compound comprising a fumarate functional group may also comprise an unsaturated polyester comprising a fumarate functional group synthesized by other methods, such as copolymerization of an epoxide and maleic anhydride.
  • the unsaturated polyester may further comprise other functional groups, such as a hydroxyl group.
  • the unsaturated polyester may comprise a liquid.
  • the dienophile-containing compound may comprise a dienophile equivalent weight of at least 100 g/eq, such as at least 200 g/eq.
  • the dienophile-containing compound may comprise a dienophile equivalent weight of no more than 3,000 g/eq, such as no more than 1,500 g/eq.
  • the dienophile-containing compound may comprise a dienophile equivalent weight of 100 g/eq to 3,000 g/eq, such as 200 g/eq to 1 ,500 g/eq.
  • the composition may comprise the furan functional groups on the first compound and the dienophile functional groups on the dienophile-containing compound in an equivalence ratio of at least 0.5:1, such as at least 0.6:1.
  • the composition may comprise the furan functional groups on the first compound and the dienophile functional groups on the dienophile-containing compound at a molar ratio of no more than 2:1, such as no more than 1.5:1.
  • the composition may comprise the furan functional groups on the first compound and the dienophile functional groups on the dienophile-containing compound at a molar ratio of 0.5:1 to 2:1, such as 0.6:1 to 1.5:1.
  • the composition of the present disclosure may comprise a thermally expandable material.
  • the thermally expandable material may be present in the first component, the second component, and/or a third component.
  • Suitable examples of thermally expandable material may comprise inorganic salts and/or thermally expandable graphite, such as thermally expandable graphite available from ACS Material.
  • the thermally expandable material may comprise thermally expandable capsules.
  • the thermally expandable capsules may comprise thermally expandable hollow capsules.
  • the thermally expandable capsules may comprise a thermoplastic resin and/or a volatile material such as a volatile hydrocarbon and/or a volatile gas.
  • the thermally expandable capsules may comprise a thermoplastic resin shell with a volatile material core. Suitable thermally expandable materials comprise Expancel available from Nouryon, Advancell available from Sekisui, and the like.
  • the thermally expandable material may have an average initial (i.e., preexpansion) particle size of at least 0.5 pm measured by methods known to those skilled in the art, such as laser diffraction or Low Angle Laser Light Scattering (LALLS), such as at least 1 m, such as at least 2 pm, such as at least 3 pm, such as at least 5 pm, such as at least 10 pm.
  • LALLS Low Angle Laser Light Scattering
  • the thermally expandable material may have an average initial particle size of no more than 100 pm measured by methods known to those skilled in the ait, such as laser diffraction or Low Angle Laser Light Scattering (LALLS), such as no more than 80 pm, such as no more than 60 pm, such as no more than 50 pm.
  • the thermally expandable material may have an average initial particle size of 0.5 pm to 100 pm measured by methods known to those skilled in the art, such as laser diffraction or Low Angle Laser Light Scattering (LALLS), such as 1 pm to 80 pm, such as 2 pm to 60 pm, such as 3 pm to 50 pm, such as 5 pm to 50 pm, such as 10 pm to 50 pm.
  • LALLS Low Angle Laser Light Scattering
  • the thermally expandable material may have an expansion temperature of at least 60°C, such as at least 70°C, such as at least 80°C, such as at least 90°C, such as at least 100°C, such as at least 110°C, such as at least 120°C, such as at least 130°C, such as at least
  • 140°C such as at least 150°C, such as at least 160°C, such as at least 170°C, such as at least
  • the increase in particle size may be, for example, the result of the volatile material beginning to expand while the thermoplastic resin shell softens.
  • Expansion temperature may be achieved, for example, by heating the coating comprising the thermally expandable material and/or heating the substrate on which the coating is formed.
  • the coating and/or the substrate may be heated by direct thermal exposure and/or, in substrates containing ferromagnetic materials, ferrimagnetic materials, and/or superparamagnetic materials or in coatings formed from compositions containing ferromagnetic materials, ferrimagnetic materials, and/or superparamagnetic materials, by indirect heating through the application of a magnetic field resulting in ferromagnetic heating, ferrimagnetic heating, and/or superparamagnetic heating.
  • the composition may comprise the thermally expandable material in an amount of at least 0.1 percent by weight based on total weight of the composition, such as such as at least 1 percent by weight.
  • the composition may comprise the thermally expandable material in an amount of no more than 20 percent by weight based on total weight of the composition, such as no more than 10 percent by weight, such as less than 10 percent by weight, such as no more than 5 percent by weight.
  • the composition may comprise the thermally expandable material in an amount of 0.1 percent to 20 percent by weight based on total weight of the composition, such as 1 percent by weight to 10 percent by weight, such as 1 percent by weight to less than 10 percent by weight, such as 1 percent by weight to 5 percent by weight.
  • compositions disclosed herein may further comprise a filler.
  • the filler may be present in the first component, the second component, and/or a third component.
  • the filler may comprise particles of a single type of filler material or may comprise particles of two or more types of filler materials. That is, the filler may comprise particles of a first filler material and may further comprise particles of a second (and a third, a fourth, etc.) filler material that is different from the first filler material.
  • first As used herein with respect to types of filler material, reference to “first,” “second,” etc., is for convenience only and does not refer to order of addition to the composition or the like.
  • the composition may comprise the filler in an amount of at least 1% by weight based on total weight of the composition, such as no more than 50% by weight.
  • the composition may comprise the filler in an amount of at least 50% by weight based on total weight of the composition, such as no more than 90% by weight.
  • the composition may comprise the filler in an amount up to 90% by weight based on total weight of the composition, such as 1% to no more than 50% by weight, or such as 50% to 90% by weight.
  • the filler may comprise a thermally conductive, electrically insulative filler (referred to herein as “TC/EI filler” and described in more detail below) and/or a thermally conductive, electrically conductive filler (referred to herein as “TC/EC filler” and described in more detail below).
  • the TC/EI and/or TC/EC (referred to collectively as “thermally conductive fillers”) may be present in the first component, the second component and/or a third component.
  • the thermally conductive filler may comprise an organic or inorganic material and may comprise particles of a single type of filler material or may comprise particles of two or more types of TC/EI filler and/or two or more types of TC/EC filler.
  • the filler may comprise a first TC/EI filler and may further comprise at least a second (i.e., a second, a third, a fourth, etc.) TC/EI filler in addition to the first TC/EI filler.
  • the filler may comprise a first TC/EC filler and may further comprise at least a second (i.e., a second, a third, a fourth, etc.) TC/EC filler in addition to the first TC/EC filler.
  • reference to “first,” “second”, etc. is for convenience only and does not refer to order of addition to the composition or the like.
  • the filler may comprise a surface coating.
  • the surface coating may comprise a silane an amino-silane, and/or or a polymer with multiple functional groups that can bind to or interact with the filler.
  • the filler may have an average particle size in at least one dimension of at least 0.01 m, as reported by the manufacturer or measured as described below, such as at least 2 pm, such as at least 10 pm, and may have an average particle size in at least one dimension of no more than 500 pm as reported by the manufacturer or measured as described below, such as no more than 400 pm, such as no more than 300 pm, such as no more than 100 pm.
  • the filler may have an average particle size in at least one dimension of 0.01 pm to 500 pm as reported by the manufacturer or measured as described below, such as 0.1 pm to 400 pm, such as 2 pm to 300 pm, such as 10 pm to 100 pm.
  • Particle sizes may be measured by methods known to those skilled in the ait, for example, using a scanning electron microscope (SEM), such as a Quanta 250 FEG SEM or an equivalent instrument.
  • SEM scanning electron microscope
  • powders may be dispersed on segments of carbon tape attached to aluminum stubs and coated with Au/Pd for 20 seconds. Samples then may be analyzed in an SEM under high vacuum (accelerating voltage lOkV and spot size 3.0), measuring 30 particles from three different areas to provide an average particle size for each sample.
  • SEM scanning electron microscope
  • the thermally conductive filler may comprise particles each having, for example, a platy, spherical, or acicular shape, and agglomerates thereof.
  • platy refers to a two-dimensional material having a substantially flat surface and that has a thickness in one direction that is less than 25% of the largest dimension.
  • the thermally conductive filler may have a thermal conductivity of at least 5 W/m K at 25°C (measured according to ASTM D7984-21), such as at least 18 W/mK, such as at least 55 W/mK, and may have a thermal conductivity of no more than 3,000 W/mK at 25°C, such as no more than 1,400 W/m K, such as no more than 450 W/m K.
  • the thermally conductive filler may have a thermal conductivity of 5 W/m K to 3,000 W/m K at 25°C, such as 18 W/m K to 1,400 W/mK, such as 55 W/m K to 450 W/m K. Thermal conductivity may be measured according to ASTM D7984-21.
  • the filler may be electrically insulative.
  • the electrically insulative filler may have a volume resistivity of at least 1 Q-m, such as at least 10 Q-m, such as at least 100 Q-m. Electrical insulation may be measured according to ASTM D257- 19.
  • the filler may be electrically conductive.
  • the electrically conductive filler may have a volume resistivity of less than 1 Q-m (measured according to ASTM D257-19), such as less than 0.1 Q-m.
  • Suitable TC/EI fillers include boron nitride (for example, commercially available as CarboTherm from Saint-Gobain, as CoolFlow and PolarTherm from Momentive, and as hexagonal boron nitride powder available from Panadyne), silicon nitride, or aluminum nitride (for example, commercially available as aluminum nitride powder available from Micron Metals Inc., and as Toyalnite from Toyal), metal oxides such as Boehmite, Pseudo Boehmite, aluminum oxide (for example, commercially available as Microgrit from Micro Abrasives, as Nabalox from Nabaltec, as Aeroxide from Evonik, and as Alodur from Imerys), magnesium oxide, beryllium oxide, titanium oxide, zinc oxide, nickel oxide, copper oxide, or tin oxide, metal hydroxides such as aluminum hydroxide or magnesium hydroxide, arsenides such as boron arsenide,
  • thermally conductive filler may be used alone or in a combination of two or more.
  • the TC/ET filler may also be ferromagnetic, ferrimagnetic, and/or supcrparamagnctic.
  • Suitable TC/EC fillers include metals such as silver, zinc, copper, gold, or metal coated hollow particles, carbon compounds such as, graphite (such as Timrex commercially available from Imerys or ThermoCarb commercially available from Asbury Carbons), carbon black (such as Vulcan commercially available from Cabot Corporation), carbon fibers (for example, commercially available as milled carbon fiber from Zoltek), graphene and graphenic carbon particles (for example, xGnP graphene nanoplatelets commercially available from XG Sciences, and/or for example, the graphenic carbon particles described below), carbonyl iron, copper (such as spheroidal powder commercially available from Sigma Aldrich), zinc (such as Ultrapure commercially available from Purity Zinc Metals and Zinc Dust XL and XLP available from US Zinc), and the like.
  • graphite such as Timrex commercially available from Imerys or ThermoCarb commercially available from Asbury Carbons
  • carbon black such as Vulcan commercially
  • graphenic carbon particles include carbon particles having structures comprising one or more layers of one-atom- thick planar- sheets of sp2-bonded carbon atoms that are densely packed in a honeycomb crystal lattice.
  • the average number of stacked layers may be less than 100, for example, less than 50.
  • the average number of stacked layers may be 30 or less, such as 20 or less, such as 10 or less, such as 5 or less.
  • the graphenic carbon particles may be substantially flat; however, at least a portion of the planar- sheets may be substantially curved, curled, creased, or buckled.
  • the particles typically do not have a spheroidal or equiaxed morphology. Suitable graphenic carbon particles are described in U.S. Publication No.
  • the term “substantially flat” means planar; “curved” or “curled” materials deviate from planarity by having a non-zero curvature; and “creased” or “buckled” indicates that at least a portion of the area is thicker than one sheet, such that the plane is doubled or folded upon itself.
  • the TC/EC filler also may be ferromagnetic, ferrimagnetic, and/or superparamagnetic.
  • the thermally conductive filler may be present in the first component, the second component, the third component, and/or a higher component.
  • the compositions disclosed herein may comprise a thermally conductive filler in an amount of at least 14.5 percent by weight based on total weight of the composition, such as at least 25 percent by weight.
  • the compositions disclosed herein may comprise a thermally conductive filler in an amount of no more than 90 percent by weight based on total weight of the composition, such as no more than 60 percent by weight.
  • the compositions disclosed herein may comprise a thermally conductive filler in an amount of 14.5 percent by weight to 90 percent by weight based on total weight of the composition, such as 25 percent by weight to 60 percent by weight.
  • the composition may comprise the thermally conductive filler in an amount of 100 percent by volume based on total volume of filler.
  • the composition may comprise the thermally conductive filler in an amount of no more than 90 percent by volume, such as no more than 80 percent by volume.
  • the composition may comprise the thermally conductive filler in an amount of at least 20 percent by volume based on total volume of filler, such as at least 50 percent by volume.
  • the composition may comprise the thermally conductive filler in an amount of 20 percent to 90 percent by volume based on total volume of filler, such as 50 percent by volume to 80 percent by volume.
  • the filler may comprise a non-thermally conductive, electrically insulative filler (referred to herein as “NTC/EI” filler).
  • NTC/EI non-thermally conductive, electrically insulative filler
  • the NTC/EI filler is in addition to the thermally expandable materials described above.
  • the NTC/EI filler may be present in the first component, the second component, and/or a third component.
  • the NTC/EI filler may comprise an organic or inorganic material and may comprise particles of a single type of filler material or may comprise particles of two or more types of NTC/EI filler.
  • the composition may comprise a first NTC/EI filler and may further comprise at least a second (i.e., a second, a third, a fourth, etc.) NTC/EI filler in addition to the first NTC/EI filler.
  • the NTC/EI filler may comprise any of the surface coatings and may have the particle sizes described above with respect to the thermally conductive fillers.
  • the NTC/EI filler may comprise particles each having, for example, a platy, spherical, or acicular shape, and agglomerates thereof, as described above with respect to the thermally conductive filler.
  • the NTC/EI filler may have a thermal conductivity of less than 5 W/m K at 25°C (measured according to ASTM D7984-21 ), such no more than 3 W/m K, such as no more than 1 W/mK, such as no more than 0.1 W/mK, such as no more than 0.05 W/mK, such as 0.02 W/m K at 25°C to 5 W/m K at 25°C. Thermal conductivity may be measured as described above.
  • the NTC/EI may have a volume resistivity of at least 1 Q-m (measured according to ASTM D257-19), such as at least 10 Q m, such as at least 100 Q-m.
  • Suitable NTC/EI fillers include but are not limited to mica, wollastonite, calcium carbonate, glass microspheres, clay, silicon dioxide, or combinations thereof.
  • the term “mica” generally refers to sheet silicate (phyllosilicate) minerals.
  • the mica may comprise muscovite mica.
  • Muscovite mica comprises a phyllosilicate mineral of aluminum and potassium with the formula KA12(AlSi30io)(F,OH)2 or (KF)2(Al 2 O3)3(SiO )6(H 2 O).
  • Exemplary non-limiting commercially available muscovite mica include products sold under the trade name MinnesotaPURETM, such as MinnesotaPURETM 700, MinnesotaPURETM 1500, MinnesotaPURETM 2400, MinnesotaPURETM 3000, DakotaPURETM 3500 and MinnesotaPURETM 4000, available from Pacer Minerals.
  • Wollastonite comprises a calcium inosilicate mineral (CaSiO s) that may contain small amounts of iron, aluminum, magnesium, manganese, titanium and/or potassium.
  • the wollastonite may have a B.E.T. surface area of 1.5 to 2.1 m 2 /g, such as 1.8 m 2 /g and a median particle size of 6 microns to 10 microns, such as 8 microns.
  • Non-limiting examples of commercially available wollastonite include NY AD 400 available from NYCO Minerals, Inc.
  • the calcium carbonate may comprise a precipitated calcium carbonate or a ground calcium carbonate.
  • the calcium carbonate may or may not be surface treated, such as treated with stearic acid, such as Socal® 312, commercially available from IMERYS.
  • Non-limiting examples of commercially available precipitated calcium carbonate include Ultra-Pflex®, Albafil®, and Albacar HO® available from Specialty Minerals and Winnofil® SPT available from Solvay.
  • Non-limiting examples of commercially available ground calcium carbonate include DuramiteTM available from IMERYS and Marblewhite® available from Specialty Minerals.
  • Useful clay minerals include a non-ionic platy filler such as talc, pyrophyllite, chlorite, vermiculite, or combinations thereof.
  • the glass microspheres may be hollow borosilicate glass.
  • Non-limiting examples of commercially available glass microspheres include 3M Glass bubbles type VS, K series, and S series available from 3M.
  • NTC/EI filler may be present in the first component, the second component, the third component and/or the higher component.
  • the compositions disclosed herein may comprise NTC/EI filler in an amount of at least 0.5 percent by weight based on total weight of the composition, such as at least 1 percent by weight, such as at least 1.5 percent by weight.
  • the compositions disclosed herein may comprise NTC/EI filler in an amount of no more than 30 percent by weight based on total weight of the composition, such as no more than 20 percent by weight, such as no more than 10 percent by weight.
  • compositions disclosed herein may comprise NTC/EI filler in an amount of up to 30 percent by weight based on total weight of the composition, such as 0.5 percent by weight to 30 percent by weight, such as 1 percent by weight to 20 percent by weight, such as 1.5 percent by weight to 10 percent by weight.
  • the composition may further comprise a third compound that is reactive with the isocyanate functional group.
  • the third compound may be present in the second component and/or a third or more component.
  • the third compound may comprise a hydroxyl functional group, such as a polyol.
  • Suitable polyols include diols, triols, tetraols, and higher functional polyols. Combinations of such polyols may also be used.
  • the polyol may comprise polyhydric alcohols such as ethylene glycol, propanediol, neopentyl glycol, butanediol, pentanediol, hexanediol, cyclohexanedimethanol, cyclohexanediol, benzenedimethanol, 4,4’isopropylidenedicyclohexanol, glycerol, trimethylolpropane, pentaerythritol, di(trimethylolpronane) or di(pentaerythritol).
  • Suitable polyols may also include polyether polyols, polyester polyols, acrylic polyols, polybutadiene polyols, hydrogenated polybutadiene polyols, polycarbonate polyols, polysiloxane polyols, and combinations thereof.
  • the polyol may comprise a polycaprolactone-based polyol.
  • the polycaprolactone-based polyols may comprise diols terminated with primary hydroxyl groups.
  • Commercially available polycaprolactone-based polyols include those sold under the trade name CapaTM from Perstorp Group, such as, for example, Capa 2054, Capa 2077A, Capa 2085, Capa 2205, Capa 3031, Capa 3050, Capa 3091, and Capa 4101.
  • the polyol may comprise a polyether polyol.
  • the polyols may be based on a polyether chain derived from ethylene glycol, propylene glycol, butylene glycol, hexylene glycol, and the like, or mixtures thereof.
  • the polyol may comprise a tetrahydrofuran-based polyol.
  • the polytetrahydrofuran-based polyols may comprise diols, triols, or tetraols terminated with primary hydroxyl groups.
  • polytetrahydrofuran-based polyols include those sold under the trade name Terathane®, such as Terathane® PTMEG 250, Terathane® PTMEG 650, and Terathane® PTMEG 1000 which are blends of linear diols in which the hydroxyl groups are separated by repeating tetramethylene ether groups, available from Invista.
  • Terathane® such as Terathane® PTMEG 250, Terathane® PTMEG 650, and Terathane® PTMEG 1000 which are blends of linear diols in which the hydroxyl groups are separated by repeating tetramethylene ether groups, available from Invista.
  • polyols based on dimer diols sold under the trade names Pripol®, SolvermolTM and Empol®, available from Cognis Corporation, or bio-based polyols, such as the tetrafunctional polyol Agrol 4.0, available from BioBased Technologies may also be utilized.
  • the composition may comprise the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound in an equivalence ratio of at least 0.2:1, such as at least 0.4:1, such as at least 0.6:1.
  • the composition may comprise the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound in an equivalence ratio of no more than 3: 1, such as no more 2:1, such as no more than 1.5:1.
  • the composition may comprise the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound in an equivalence ratio of 0.2:1 to 3:1, such as 0.4:1 to 2:1, such as 0.6:1 to 1.5:1.
  • the composition may further comprise a fourth compound comprising a furan functional group that is different from the compounds disclosed herein.
  • the fourth compound may be present in the first component and/or a third or more component. This language is not intended to be limiting and does not exclude the possibility of the composition comprising more than two compounds comprising a furan functional group, such as three compounds, such as four compounds.
  • the fourth compound may comprise a furan equivalent weight of at least 68 g/eq, such as at least 80 g/eq.
  • the fourth compound may comprise a furan equivalent weight of no more than 1,500 g/eq, such as no more than 1,000 g/eq.
  • the fourth compound may comprise a furan equivalent weight of 68 g/eq to 1,500 g/eq, such as 80 g/eq to 1,000 g/eq.
  • the composition may optionally comprise one or more additives.
  • an “additive” refers to a rheology modifier, a tackifier, a thermoplastic polymer, a surfactant, a flame retardant, a corrosion inhibitor, a UV stabilizer, a colorant, a tint, a solvent, a plasticizer, an adhesion promoter, an antioxidant, a silane, and/or a moisture scavenger.
  • compositions provided by the present disclosure can comprise a flame retardant or combination of flame retardants.
  • Certain thermally conductive materials such as aluminum hydroxide and magnesium hydroxide, for example, also may be flame retardants; for purposes of calculating weight percentages herein, such materials are counted as thermally conductive materials.
  • flame retardant refers to a material that slows down or stops the spread of fire or reduces its intensity. Flame retardants may be available as a powder that may be mixed with a composition, a foam, or a gel.
  • flame retardant when the compositions disclosed herein include a flame retardant, such compositions may form a coating on a substrate surface and such coating may function as a flame retardant.
  • a flame retardant can include a mineral, an organic compound, an organohalogen compound, an organophosphorous compound, or a combination thereof.
  • the composition may comprise the additive in an amount of at least 0.01 % by weight based on total weight of the composition, such as at least 0.1% by weight.
  • the composition may comprise the additive in an amount of no more than 15% by weight based on total weight of the composition, such as no more than 10% by weight.
  • the composition may comprise the additive in an amount of 0.01% to 15% by weight based on total weight of the composition, such as 0.1% to 10% by weight.
  • composition of the present disclosure may further comprise elastomeric particles.
  • elastomeric particles refers to particles comprising one or more materials having a glass transition temperature (Tg) of greater than -150°C and less than 30°C, calculated, for example, using the Fox Equation.
  • the elastomeric particles may have a core/shell structure. Suitable core-shell elastomeric particles may be comprised of an acrylic shell and an elastomeric core.
  • the core may comprise natural or synthetic rubbers, polybutadiene, styrene-butadiene, polyisoprene, chloroprene, acrylonitrile butadiene, butyl rubber, polysiloxane, polysulfide, ethylene-vinyl acetate, fluoroelastomer, polyolefin, or combinations thereof.
  • the elastomeric particles may comprise a polybutadiene core, a styrene butadiene core, and/or a polysiloxane core.
  • An exemplary non-limiting commercial core-shell elastomeric particle product using poly(butadiene) rubber particles that may be utilized in the composition of the present disclosure include core-shell poly(butadiene) rubber powder (commercially available as PARALOIDTM EXL 2650A from Dow Chemical).
  • Exemplary non-limiting commercial core- shell elastomeric particle products using styrene-butadiene rubber particles that may be utilized in the composition include a coreshell styrene-butadiene rubber powder (commercially available as CLEARSTRENGTH® XT100 from Arkema or as PARALOIDTM EXL 2650J), and a core-shell styrene-butadiene rubber dispersion (25% core- shell rubber by weight) in polypropylene glycol (MW 400) (commercially available as Kane Ace MX 715 from Kaneka Texas Corporation).
  • MW 400 polypropylene glycol
  • Exemplary non-limiting commercial core- shell elastomeric particle products using polysiloxane rubber particles that may be utilized in the composition of the present disclosure include a core-shell polysiloxane rubber powder (commercially available as GENIOPERL® P52 from Wacker).
  • the composition may comprise the elastomeric particles in an amount of at least 0.1% by weight based on total weight of the composition, such as at least 1% by weight.
  • the composition may comprise the elastomeric particles in an amount of no more than 50% by weight based on total weight of the composition, such as no more than 20% by weight.
  • the composition may comprise the elastomeric particles in a positive amount up to 25% by weight based on total weight of the composition, such as 0.1% to 50% by weight, such as 1% to 20% by weight.
  • composition optionally may further comprise a dispersant.
  • a dispersant refers to a substance that may be added to the composition to improve the separation of the thermally conductive filler particles by wetting the particles and breaking apart agglomerates.
  • Suitable dispersants for use in the composition include fatty acid, phosphoric acid esters, polyurethanes, polyamines, polyacrylates, polyalkoxylates, sulfonates, polyethers, and polyesters, or any combination thereof.
  • Non-limiting examples of commercially available dispersants include ANTLTERRA-U100, DISPERBYK-102, DISPERBYK-103, DISPERBYK- 111, DISPERBYK-171, DISPERBYK-2151, DISPERBYK-2152, DISPERBYK-2059, DISPERBYK-2000, DISPERBYK-2117, and DISPERBYK-2118 available from BYK Company; and SOLSPERSE 24000SC, SOLSPERSE 16000 and SOLSPERSE 8000 hyperdispersants available from The Lubrizol Corporation, and Tegowet 270, Tegowet 500, TEOG® Dispcrs 670, and Tegowet 550 available from Evonik.
  • the composition may comprise a dispersant in an amount of at least 0.5 percent by weight based on total weight of the composition, such as at least 1 percent by weight.
  • the composition may comprise a dispersant in an amount of no more than 10 percent by weight based on total weight of the composition, such as no more than 5 percent by weight.
  • the composition may comprise a dispersant in an amount of more than 0 percent by weight to 10 percent by weight based on total weight of the composition, such as 0.5 percent by weight to 10 percent by weight, such as 1 percent by weight to 5 percent by weight.
  • the composition may further comprise an accelerator.
  • the accelerator may be present in the first component, the second component, and/or a third or higher component.
  • the accelerator may comprise an amine or nitrogen-based catalyst.
  • the accelerator may comprise a tertiary amine, an /V-heterocyclic carbene, or an amidine/guanidine.
  • Suitable accelerators that may be used in the present disclosure include A /V-dimethylcyclohexylamine, /V.A imcthylcthanola inc, N- methyl morpholine, 2,2’ -dimorpholinodiethylether, dimethylaminoethoxyethanol, triethylenediamine, bis(2-dimethylaminoethyl)ether, N,N,N'- trimethylaminoethylethanolamine, A/,Al,7V’,Al’-tetramethyl- 1 ,6-hexanediamine, 1,3,5- tris(dimethylaminopropyl)-hexahydro-s-triazine, 1 ,8-diazabicyclo[5.4.0]undec-7-ene, N-(3- aminopropyl)imidazole, 1,2-dimethylimidazole, l,5,7-triazabicyclo[4.4.0]dec-5-ene, or
  • the accelerator may comprise an organic acid, such as diphenyl phosphate, methanesulfonic acid, or triflic acid.
  • the accelerator may comprise an organometallic complex. Suitable organometallic complexes comprise titanates, such as tetrabutyl titanate or tetrapropyl titanate, tin compounds, such as dibutyltin dilaurate, dibutyltin diacetate, tin octoate, or dibutyl tin oxide, or other metal compounds, such as chelates of bismuth, zirconium, titanium, aluminum, or iron, such as zirconium acetylacetonate or iron acetylacetonate.
  • the accelerator may be latent, blocked, and/or encapsulated.
  • the composition may comprise the accelerator in an amount of at least 0.001% by weight based on total weight of the composition, such as at least 0.01% by weight, and may be present in an amount of no more than 2% by weight based on total weight of the composition, such as no more than 1% by weight.
  • the accelerator may be present in the composition in an amount of 0.001 % to 2% by weight based on total weight of the composition, such as 0.01% to 1% by weight.
  • the composition may comprise the accelerator in an amount up to 2% by weight based on total weight of the composition, such as in an amount up to 1% by weight.
  • the first component and the second component may be liquid at ambient conditions, may be mixable at ambient temperature, and may be capable of curing at ambient temperature.
  • the composition may be formulated as a two-component composition.
  • compositions disclosed herein may be formulated as a free-standing film, an adhesive, a structural adhesive, a sealant, a pottant, a gap filler, a pre-preg, an embedding material, an encapsulant or the like.
  • the composition may have a reflow onset temperature of at least 50°C, such as at least 60°C.
  • the composition may have a reflow onset temperature of less than 150°C, such as less than 140°C.
  • the composition may have a reflow onset temperature of 50°C to 150°C, such as 60°C to 140°C.
  • the reflow onset temperature may be achieved, for example, by heating the coating comprising the coatings disclosed herein and/or heating the substrate on which the coating is formed.
  • the coating and/or the substrate may be heated by directed thermal exposure and/or, in substrates containing ferromagnetic materials, ferrimagnetic materials, and/or superparamagnetic materials or in coatings formed from compositions containing ferromagnetic materials, ferrimagnetic materials, and/or superparamagnetic materials, by indirect heating through the application of a magnetic field resulting in ferromagnetic heating, ferrimagnetic heating, and/or superparamagnetic heating.
  • compositions described above may be applied alone or as part of a system that can be deposited in different ways onto different substrates. Accordingly, disclosed herein are methods for treating a substrate comprising, or consisting essentially of, or consisting of, contacting a surface of the substrate with any of the compositions disclosed herein. “Contacting a surface of the substrate” encompasses contacting a surface of a substrate that has been treated with other coatings, as described herein. Optionally, the method may comprise mixing the first component and the second component to form the composition.
  • composition can be applied to the surface of a substrate in different ways, non-limiting examples of which include brushing, rolling, as a film, as pellets, troweling, via spatulas, dipping, via spray guns, or via applicator guns to form a coating or the substrate surface.
  • the composition After application to the substrate(s), the composition can be cured.
  • the composition may be allowed to cure at room temperature or slightly thermal conditions, and for any desired time (e.g., from 5 minutes to 1 hour) sufficient to cure the composition on the substrate(s).
  • the composition may be further cured by heating at an elevated temperature following the contacting of the substrate surface with the composition, such as at a temperature of less than 90°C, such as less than 80°C, such as less than 70°C, such as less than 60°C, but greater than ambient, such as greater than 40°C, such as greater than 50°C, and for any desired time (e.g., from 5 minutes to 1 hour) sufficient to cure the composition on the substrate(s), provided that, in compositions comprising a thermally expandable material, the thermal conditions are lower than the expansion temperature of the thermally expandable material.
  • the composition may form a coating on the substrate surface.
  • the coating may be, for example, an adhesive such as a structural adhesive, a pottant, a pre-preg, a liquid shim, a seal, or a gap filler.
  • the composition may be cured to form an article, such as by additive manufacturing, such as three-dimensional (“3D”) printing as described below.
  • the composition may have a Tg of at least -120°C (measured using a TA Instruments Q800 DMA V21.3 in single cantilever mode).
  • the composition may have a Tg of no more than 150°C, such as no more than 100°C, such as up to 90°C (measured using a TA Instruments Q800 DMA V21.3 in single cantilever mode).
  • the composition may have a Tg of - 120°C to 150°C, such as -120°C to 100°C (measured using a TA Instruments Q800 DMA V21.3 in single cantilever mode).
  • the coatings disclosed herein are cured to form a thermally expandable coating prior to expansion of the thermally expandable material.
  • the method optionally may further comprise contacting a surface of a second substrate to the composition such that the composition is between the first substrate and the second substrate.
  • the composition may be applied to either one or both of the first and second substrates such that the composition is positioned between the first and the second substrates.
  • the substrates may be aligned, and pressure and/or spacers may be added to control bond thickness.
  • compositions may be applied to cleaned or uncleaned (i.e., including oil or oiled) substrate surfaces.
  • the compositions disclosed herein may also be applied to a substrate that has been pretreated, coated with an electrodepositable coating, and/or coated with additional coatings such as a primer, basecoat, or topcoat.
  • the composition may be injected or otherwise placed in a die caster or a mould and dried or cured under ambient conditions or by exposure to an external energy source, for example, such as by heating to a temperature of less than 180°C, such as less than 130°C, such as less than 90°C to form a part or a member and optionally may be machined to a particular configuration.
  • an external energy source for example, such as by heating to a temperature of less than 180°C, such as less than 130°C, such as less than 90°C to form a part or a member and optionally may be machined to a particular configuration.
  • compositions disclosed herein may be applied to a substrate surface and cured as described above to form a coating.
  • the coatings may be, for example, an adhesive, such as a structural adhesive, a sealant, a gap filler, a pottant, and/or a liquid shim.
  • Thermally expandable coatings disclosed herein may have a pre-expansion thermal conductivity of at least 0.5 W/m-K at 25°C measured according to ASTM D7984-21 using a modified transient plane source instrument, such as at least 1 W/m-K, such as at least 2 W/m K, such as at least 3 W/m-K, such as at least 4 W/m-K, such as at least 5 W/m-K.
  • the preexpansion thermal conductivity of the thermally expandable coatings was not reduced by the addition of the thermally expandable material.
  • Thermally expandable coatings disclosed herein may have a decrease in thermal conductivity post-expansion (following exposure to at least the expansion temperature of the thermally expandable material) relative to pre-expansion thermal conductivity (measured at 25°C according to ASTM D7984-21 using a modified transient plane source instrument) of at least 10%, such as at least 25%, such as at least 50%, such as at least 75%, such as at least 95%, such as at least 96%, such as at least 97%, such as at least 98%, such as at least 99%.
  • the thermally expandable material may have an expansion volume ratio (i.e. , post-expansion volume / pre-expansion volume) of greater than 1 when measured at 25°C and by methods known to those skilled in the art, such as SEM, laser diffraction, or LALLS, such as at least 1.1, such as at least 1.2, such as at least 1.5, such as at least 2, such as at least 2.5, such as at least 3, such as at least 4, such as at least 5, such as at least 10, such as at least 11, such as at least 12, such as at least 20, such as at least 50, such as at least 75, such as at least 100, such as at least 125, such as at least 175, such as at least 200, such as 10 to 150, such as 10 to 100.
  • an expansion volume ratio i.e. , post-expansion volume / pre-expansion volume
  • thermally expandable coatings disclosed herein may be cohesive following exposure to the expansion temperature of the thermally expandable material.
  • thermally expandable coatings disclosed herein may be non- cohesive/crumbling following exposure to the expansion temperature of the thermally expandable material.
  • the thermally expandable coatings i.e., post-cure
  • may have a post-expansion volume ratio of greater than 1, such as at least 1.1, such as at least 1.2, such as at least 1.5, such as at least 2, such as at least 3, such as at least 5, such as at least 10, such as at least 20, wherein the post-expansion volume ratio post-expansion volume (measured at 25 °C following exposure to at least the expansion temperature of the thermally expandable material) / pre-expansion volume (measured at 25 °C prior to exposure to at least the expansion temperature of the thermally expandable material) and wherein volumes are measured using a caliper and the coating is cohesive/non-crumbling.
  • compositions are highly loaded compositions (i.e., contain filler in an amount of 50% by weight up to 90% by weight based on total weight of the composition in combination with thermally expandable material in an amount of 0.5% by weight to 10% by weight based on total weight of the composition), the compositions were found to be pumpable (i.e., each component having a viscosity of no more than 10 6 Pa-s at a shear stress of 1 Hz measured by an Anton Paar MCR 301 rotational rheometer at 25 °C using a parallel plate with a diameter of 25 mm (1 mm gap)). This was a surprising result.
  • the coating may be cohesive following exposure to the expansion temperature of the thermally expandable material.
  • the coating may be non-cohesive/crumbling following exposure to the expansion temperature of the thermally expandable material, which can be useful for removal of the coating from a substrate surface, such as removability of a battery cell from a battery pack.
  • the thermally expandable coatings disclosed herein may exhibit a vertical burning test rating of VO (measured by the UL-94 vertical flame test procedure).
  • a rating of VO means that (1) no burning combustion (flaming or glowing) is observed for more than 10 seconds after a flame is removed from first and second flame exposure, (2) no glowing combustion was observed for more than 30 seconds after a flame is removed from second flame exposure, and (3) no dripping of any flame particles that result in igniting the surgical cotton is observed.
  • the thermally expandable coatings disclosed herein may exhibit a preexpansion lap shear strength of at least 5 MPa at 25°C measured according to ASTM D1002-10 using 2024 T3 aluminum substrate of 0.063-inch thickness, as measured by an INSTON 5567 machine in tensile mode with a pull rate of 1.3 mm per minute, such as at least 10 MPa.
  • any of the substrates disclosed herein may comprise a dielectric coating in addition to the thermally expandable coating.
  • the dielectric coating composition and the thermally expandable coating composition may form continuous or discontinuous coatings, provided that the coatings overlap to form a coating stack, e.g., a thermally expandable coating formed from the thermally expandable coating composition on a dielectric coating formed from the dielectric coating composition.
  • a coating stack does not preclude the possibility of coatings in addition to the dielectric coating and the second coating, wherein such additional coatings may or may not be positioned between the dielectric coating and the second coating.
  • the coating stack may be formed between two substrates.
  • dielectric refers to a coating composition or coating comprising a dielectric strength of at least 10 kV/mm measured using a Sefelec Dielectric Strength Tester (RMG12AC-DC; voltage limit 12.0 kV, Imax Limit 0.1 mA, 19 sec ramp, 20 sec dwell, 2 sec fall) according to ASTM D149- 09, such as at least 12 kV/mm, such as at least 15 kV/mm.
  • the coating system may comprise: a dielectric coating composition for application to a first portion of a substrate surface; and any of the thermally expandable coating compositions disclosed herein for application to a second portion of a substrate surface. In a cured state, the dielectric coating composition may form a dielectric coating. In a cured state, the thermally expandable coating composition may form a thermally expandable coating.
  • the coating kit may comprise: a dielectric coating composition for application to a first portion of a substrate surface; and any of the thermally expandable coating compositions disclosed herein for application to a second portion of the substrate surface.
  • the kit optionally may comprise instructions for applying the dielectric coating composition and the thermally expandable coating composition to the substrate surface.
  • the first portion and the second portion may be on a single substrate or may be on a first substrate and a second substrate, respectively.
  • the dielectric coating composition may comprise a binder comprising a filmforming resin.
  • a “film-forming resin” refers to one or more monomers, oligomers, prepolymers and/or polymers, such as homopolymers and/or copolymers, that can form a coating upon reaction with a curing agent or crosslinker, upon evaporation of a solvent, and/or upon photo or thermal activation.
  • the dielectric coating composition may comprise any suitable film- forming resin, including organic film-forming resins and/or inorganic film-forming resins, such as silicon-based film- forming resins.
  • suitable film- forming resins include but are not limited to polyester, alkyd, urethane, isocyanate, polyurea, epoxy, acrylic, polyether, polysulfide, polyamine, polyamide, polyvinyl chloride, polyolefin, polyvinylidene fluoride, polyvinyl chloride, polyolefin, polysiloxane, amine-aldehydes, resinous polyols, phosphatized polyepoxides, phosphatized acrylic polymers, aminoplasts, or combinations thereof.
  • Suitable curing agents include but arc not limited to amines, aminoplasts, phenoplasts, polyisocyanatcs, including blocked isocyanates, polyepoxides, beta-hydroxyalkylamides, polyacids, organometallic acidfunctional materials, polyamines, polyamides, polysulfides, polythiols, polyenes such as polyacrylates, polyols, polysilanes and the like, or combinations thereof.
  • the dielectric coating composition may comprise a thermoset coating composition, wherein the coating composition is cured upon crosslinking of a film-forming resin and a curing agent and/or crosslinker.
  • the dielectric coating composition may comprise a thermoplastic coating composition, wherein the coating composition comprises a film-forming resin that cures upon evaporation of water and/or solvent.
  • the dielectric coating composition may comprise a thermoset or thermoplastic coating composition that cures upon exposure to actinic radiation, such as ultraviolet light.
  • the dielectric coating composition may comprise a liquid coating composition or a powder coating composition.
  • liquid means a material having a viscosity less than 100,000 Pa-s at 25°C as measured by parallel plate rheology with a plate diameter of 25 mm, a gap of 0.5 mm, and a shear rate of 1 s’ 1 .
  • Suitable liquid coating compositions include but are not limited to electrodepositable coating compositions, one-component coating compositions, and/or multicomponent coating compositions.
  • the liquid dielectric coating composition may comprise an electrodepositable coating composition.
  • the electrodepositable coating composition may comprise one or more cationic or anionic salt group-containing film-forming resins that may be deposited onto a metal or other conductive substrate under the influence of an applied electrical potential, i.e., by electrodeposition.
  • the liquid dielectric coating composition may comprise a UV-curable coating composition comprising film-forming resins capable of curing upon exposure to UV radiation.
  • a UV-curable film-forming resin may be used, such as free radical polymerizable resins containing ethylenic unsaturation or olefinic double bonds and/or film-forming resins that may react through a cationic photopolymcrization mechanism.
  • suitable UV -curable coating compositions include but are not limited to the RAYCRON line of UV-curable coatings, commercially available from PPG Industries, Inc.
  • liquid dielectric coating compositions include but are not limited to the SPECTRACRON line of solvent-based coating compositions and the AQUACRON line of water-based coating compositions, all commercially available from PPG Industries, Inc.
  • the liquid dielectric coating may also be applied as a two-component composition where the filmforming resins and the reactive curing agent and/or crosslinker are mixed just before application of the coating composition and may optionally cure under ambient conditions without any external energy source.
  • the dielectric coating composition may comprise a powder coating composition.
  • “Powder coating composition” as used herein refers to any dielectric coating composition in the form of a co-reactable solid in particulate form which may be substantially free, essentially free, or completely free of water and/or solvent. Suitable filmforming resins useful in dielectric powder coating compositions include those discussed in PCT Publ. No. WO 2021/173941A1, pars. [0006] to [0042], [0057] to [0068], [0088] to [0105] and [0128] to [0139], incorporated herein by reference.
  • Non-limiting examples of suitable powder compositions include the polyester-based ENVIROCRON line of powder coating compositions (commercially available from PPG Industries, Inc.), silicon modified polyester compositions, epoxy-polyester hybrid compositions, and/or UV-curable powder compositions.
  • the dielectric coating composition may be applied to a substrate by any suitable method known in the art, including but not limited to electrodeposition, coil coating, spraying, such as electrostatic spraying, flow coating, spin coating, curtain coating, brushing, dipping, hot- melt extrusion, application of a self-supporting film, and/or by a fluidized bed process.
  • the dielectric coating composition may be cured by any method known in the ait, such as baking, induction heating, infrared heating, and/or exposure to actinic radiation such as UV.
  • the dielectric coating formed from the dielectric coating compositions disclosed herein may comprise a dielectric strength of at least 10 kV/mm, such as at least 12 kV/mm, such as at least 15 kV/mm.
  • the dielectric coating may comprise a dielectric strength of no more than 120 kV/mm, such as no more than 100 kV/mm.
  • the dielectric coating may comprise a dielectric strength of 10 kV/mm to 120 kV/mm, such as 12 kV/mm to 100 kV/mm, such as 15 kV/mm to 100 kV/mm.
  • Dielectric strength may be measured using a Sefelec Dielectric Strength Tester (RMG12AC-DC; voltage limit 12.0 kV DC, Imax Limit 0.1 mA, 19 sec ramp, 20 sec dwell, 2 sec fall) according to ASTM D 149-09.
  • RMG12AC-DC Sefelec Dielectric Strength Tester
  • compositions disclosed herein may be used in any suitable additive manufacturing technology, such as three-dimensional (3D) printing, extrusion, jetting, and binder jetting.
  • additive manufacturing refers to a process of producing a pail or member by constructing it in layers, such as one layer at a time.
  • the present disclosure is also directed to the production of structural articles, such as by way of a non-limiting example, sound damping pads, print gaskets, or seals, using an additive manufacturing process, such as 3D printing.
  • 3D printing refers to a computerized process, optionally including artificial intelligence modulation, by which materials are printed or deposited in successive layers to produce a 3D pail or member, such as, by way of a non-limiting example, sound damping pads in a battery assembly.
  • a 3D part or member may be produced by depositing successive portions or layers over a base of any spatial configuration and thereafter depositing additional portions or layers over the underlying deposited portion or layer and/or adjacent to the previously deposited portion or layer to produce the 3D printed part or member.
  • the configuration of the 3D printing process depends on factors such as the deposition volume, the viscosity of the composition, and the complexity of the part being fabricated. Any suitable mixing, delivery, and 3D printing equipment as known to those skilled in the art, may be used. Compositions may be printed or deposited in any size and/or shape of droplets or extrudate, and in any patterns to produce the 3D structure.
  • compositions as disclosed herein may be applied or deposited by any suitable 3D printing method as known to those skilled in the art.
  • the first component and the second components of the compositions disclosed herein may be mixed and then deposited, or the first component and the second component may be deposited separately, such as simultaneously and/or sequentially.
  • the first component and the second component may be premixed, i.e., mixed together, prior to application, and then deposited.
  • the mixture may be reacted or thermoset when the material is deposited; the deposited reaction mixture may react after deposition and may also react with previously deposited portions and/or subsequently deposited portions of the article such as underlying layers or overlying layers of the article.
  • the first and second components may be released from their individual storage containers and pushed, such as pumped through conduits, such as hoses, to a mixer, such as a static or dynamic mixer, wherein the composition may be mixed for a time sufficient to homogenize the composition, wherein the composition may then be released through an outlet.
  • the outlet may be a deposition device, such as a printing head, and/or the materials may exit the mixing unit and be pushed, such as by a pump, through a conduit, such as a hose, to the printing head.
  • the printing head may optionally be mounted on a 3D rotational robotic ami to allow delivery of 3D print compositions to any base in any spatial configuration and/or the base may be manipulated in any spatial configuration during the 3D printing process.
  • the first component and the second component may be deposited independently from different printing heads.
  • the first component may be deposited from one printing head and the second component may be deposited from a second printing head.
  • the first component and the second component may be deposited in any pattern such that the first component and the second component comprising any deposited layer can react together as well as react with underlying and/or overlying layers to produce the 3D printed part or member.
  • Methods provided by the present disclosure include printing the composition on a fabricated part. Methods provided by the present disclosure include directly printing parts.
  • parts can be fabricated.
  • the entire part can be formed from one of the compositions disclosed herein, one or more portions of a part can be formed from one of the compositions disclosed herein, one or more different portions of a part can be formed using the compositions disclosed herein, and/or one or more surfaces of a part can be formed from a composition provided by the present disclosure.
  • internal regions of a part can be formed from a composition provided by the present disclosure.
  • compositions disclosed herein demonstrate ambient temperature curability.
  • the coatings formed from the compositions disclosed herein also surprisingly may be used as structural adhesives.
  • the coatings formed from the compositions disclosed herein demonstrate high lap shear strength, measured at 25 °C and determined according to ASTM DI 002- 10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute, but a low lap shear strength at 150°C, determined according to ASTM D1002-10 using an Instron 5567 machine in tensile mode with a pull rate of 1.3 mm per minute. This was a surprising and unexpected result.
  • coatings formed from the compositions disclosed herein surprisingly demonstrate high expansion upon heating to 160°C. After expansion, the coatings surprisingly demonstrate a substantial reduction in thermal conductivity.
  • the articles formed from the compositions disclosed herein surprisingly may exhibit high reprocessability, reshaping, and/or self-sealing.
  • the expansion temperature of the thermally expandable material must be greater than the reflow onset temperature of the cured composition.
  • thermally expandable material did not reduce the pre-expansion thermal conductivity of the thermally expandable coatings disclosed herein.
  • compositions disclosed herein may be used to repair a joint between two substrates.
  • compositions disclosed herein may be used to form coatings having the following properties: (a) a pre-expansion thermal conductivity of at least 0.5 W/m-K at 25°C and measured as described in the Examples, such as at least 1 W/m-K, such as at least 2 W/m-K, such as at least 3 W/m-K, such as at least 4 W/m-K, such as at least 5 W/m-K; and/or
  • thermo conductivity post-expansion following exposure to thermal conditions of greater than 60°C, such as at least 70°C, such as at least 80°C, such as at least 90°C, such as at least 100°C, such as least 110°C, such as at least 120°C, such as at least 130°C, such as at least 140°C, such as at least 150°C, such as at least 160°C, such as at least 170°C, such as at least 180°C, such as at least 190°C, such as at least 200°C) relative to pre-expansion thermal conductivity (measured at 25°C as described in the Examples) of at least 10%, such as at least 25%, such as at least 50%, such as at least 75%, such as at least 95%, such as at least 96%, such as at least 97%, such as at least 98%, such as at least 99%; and/or
  • a post-expansion volume ratio of greater than 1, such as at least 1.1, such as at least 1.2, such as at least 1.5, such as at least 2, such as at least 3, such as at least 5, such as at least 10, such as at least 20, wherein the post-expansion volume ratio post-expansion volume (measured at 25°C following exposure to thermal conditions of greater than 60°C, such as at least 70°C, such as at least 80°C, such as at least 90°C, such as at least 100°C, such as least 110°C, such as at least 120°C, such as at least 130°C, such as at least 140°C, such as at least 150°C, such as at least 160°C, such as at least 170°C, such as at least 180°C, such as at least 190°C, such as at least 200°C) / pre-expansion volume (measured at 25°C prior to exposure to thermal conditions) and wherein volumes are measured using a caliper and the coating is cohesive/non-cr
  • a vertical burning test rating of V0 (measured by the UL-94 vertical flame test procedure) (a rating of V0 means that (1) no burning combustion (flaming or glowing) is observed for more than 10 seconds after a flame is removed from first and second flame exposure, (2) no glowing combustion was observed for more than 30 seconds after a flame is removed from second flame exposure, and (3) no dripping of any flame particles that result in igniting the surgical cotton is observed); and/or
  • compositions described herein may be coated or deposited on, or otherwise contacted with, any substrate or surface, such as, but not limited to metals or metal alloys, polymeric materials, such as plastics including filled and unfilled thermoplastic or thermoset materials, and/or composite materials.
  • suitable substrates include, but are not limited to, glass or natural materials such as wood.
  • Substrates may include two or more of any different materials in any combination, such as, but not limited to, two different metals, or a metal and a metal alloy, or a metal and a metal alloy and one or more composite materials.
  • Suitable substrates may include, but are not limited to, both flexible and rigid metal substrates such as ferrous metals, aluminum, aluminum alloys, magnesium, titanium, copper, and other metal and alloy substrates.
  • the ferrous metal substrates may include, for example, iron, steel, and alloys thereof.
  • useful steel materials include cold rolled steel, nickel plated cold rolled steel, galvanized (zinc coated) steel, electrogalvanized steel, stainless steel, pickled steel, zinc-iron alloy such as GALV ANNEAL, and combinations thereof.
  • Aluminum alloys such as those, for example, of the 1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, 7XXX, or 8XXX series as well as clad aluminum alloys and cast aluminum alloys, such as those, for example, of the A356, 1XX.X, 2XX.X, 3XX.X, 4XX.X, 5XX.X, 6XX.X, 7XX.X, or 8XX.X series also may be used as the substrate.
  • the substrate also may comprise, for example, magnesium, such as magnesium alloys of the AZ31B, AZ91C, AM60B, or EV31A series, titanium and/or titanium alloys, such as those of grades 1-36 including H grade variants, copper and copper alloys, or other non-ferrous metals, as well as alloys of these materials.
  • the substrate may comprise a composite material such as a plastic, fiberglass and/or carbon fiber composite.
  • the substrate may comprise a bare substrate or the substrate may be pretreated or pre-coated with one or more layers.
  • Suitable pretreatment solutions may include but are not limited to a zinc phosphate pretreatment solution such as, for example, those described in U.S. Pat. Nos. 4,793,867 and 5,588,989, or a zirconium containing pretreatment solution such as, for example, those described in U.S. Pat. Nos. 7,749,368 and 8,673,091, all of which are incorporated herein by reference.
  • the substrate may be in any form, such as, without limitation, a sheet, a foil, a laminate foil, a pad, a fabricated part, a component, or an article.
  • Compositions comprising the materials disclosed herein may be used to coat a substrate, such as by depositing, applying, or contacting the hot melt to a substrate surface.
  • the compositions, in a cured state may be used in any form, such as but not limited to, a coating, a sealant, an adhesive, a pottant, or an encapsulant, such as a solid or gel, a pad, such as a pad formed in-situ, or a discrete premanufactured or pre-formed pad.
  • the substrate may be a multi-metal article.
  • multi-metal article refers to (1) an article that has one surface comprised of a first metal and one surface comprised of a second metal that is different from the first metal, (2) a first article that has one surface comprised of a first metal and a second article that has one surface comprised of a second metal that is different from the first metal, or (3) both (1) and (2).
  • FIGS. 1 to 9 illustrate non-limiting examples of battery assembly components and constructions as well as non-limiting applications or use of compositions as disclosed herein in said battery assemblies.
  • FIGS. 1 to 9 illustrate specific examples of cell shapes and cell arrangements, cells may be arranged in any configuration known to those skilled in the art.
  • the compositions disclosed herein, in a cured state may be used to form pads, adhesives, structural adhesives, coatings, pottants and the like, to provide thermal protection between battery cells, within battery modules and/or within battery packs. These materials may be used on any surface or in any space within such battery assemblies.
  • compositions disclosed herein also may be useful in battery assemblies including, but not limited to, cell to module (FIGS. 3, 4, 6B), module to pack (FIGS. 6C, 7), cell to pack (FIG. 8), and cell to chassis battery assemblies (FIG. 9).
  • Such battery assemblies may be used in, but not limited to, any aforementioned application.
  • Battery assemblies may be any combination of one or more battery cells, the interconnection of which provide electrical conductivity between them, as well as ancillary components such as, in non-limiting examples, control electronics and components that ensure the necessary structural, mechanical, and environmental requirements for the operation of a specific battery (for example, without limitation, cell interconnectors such as wires, battery pack enclosures including trays and lids, module enclosures, module frames and frame plates, module racking, cooling and heating components including cooling plates, cooling fins, and cooling tubes, electrical busbar's, battery management systems, battery thermal management systems, chargers, inverters and converters).
  • ancillary components such as, in non-limiting examples, control electronics and components that ensure the necessary structural, mechanical, and environmental requirements for the operation of a specific battery (for example, without limitation, cell interconnectors such as wires, battery pack enclosures including trays and lids, module enclosures, module frames and frame plates, module racking, cooling and heating components including cooling plates, cooling fins, and cooling tubes, electrical busbar's, battery management systems
  • Battery cells 10 are generally single unit energy storage containers that may be connected in series or in parallel. Battery cells may be any suitable size or shape known to those skilled in the art, such as but not limited to, cylindrical (FIGS. 1, 4 and 9), prismatic (FIGS. 2, 5-8) and/or pouch (FIG. 3). Battery cells 10 are enclosed to provide desired mechanical protection and environmental isolation of the cell. For example, cylindrical and prismatic cells may be encased in metal cans, cases, and lids, while pouch cells may be enclosed in multilayer laminate foils. Battery terminals 1 connect the electrodes inside the battery cell to the electrical circuit outside the battery cell, with one being a positive terminal and the other being a negative terminal. As illustrated in FIG. 4, battery cells 10 may be connected by interconnector wires 5 with other battery cells 10 in series or in parallel to enable an electric current to flow between cells 10.
  • battery cells 10 may be arranged in modules 100 comprising multiple cells 10 connected in series or in parallel.
  • the modules 100 may include an enclosure of the arranged cells 10.
  • Ancillary components such as those aforementioned, may be included. Spaces of any dimensions may be located between the plurality of cells, ancillary components, base, and/or any interior surface of the module wall or other enclosure 120.
  • FIG. 1 illustrates a top-down view of cylindrical battery cells 10 having terminals 1. As shown, the cells are arranged in rows with either cooling tubes 3 or dielectric insulation paper (e -paper) 4 between them. As shown, materials, such as adhesive 6 and/or pottants 7 optionally formed from the compositions disclosed herein in a cured state, may be positioned between the cells 10, cooling tubes 3 and/or e-paper 4. Optionally, e-paper 4 may be replaced by one of the compositions disclosed herein.
  • FIG. 2 illustrates an exploded isometric view of an array of prismatic battery cells 10.
  • each prismatic cell 10 may comprise a top 11, a bottom, and walls 13 positioned between the top and bottom and each having a surface.
  • materials, such as pads 8 formed from the compositions disclosed herein in a cured state may be positioned between surfaces of cell walls 13 of adjacent cells 10.
  • FIG. 3 illustrates a cut-out front view of an array of pouch battery cells 10 in a module 100.
  • the module walls 120 partially or fully encase the cells 10.
  • materials, such as pads 8 formed from the compositions disclosed herein in a cured state, may be positioned between surfaces of cells 10.
  • FIG. 4 illustrates an isometric view of cylindrical cells 10 in a battery module 100.
  • Each cell may comprise a top 11, a bottom 12, and walls 13 positioned between the top and bottom and each having a surface.
  • the top 11 and the bottom 12 may be oppositely charged terminals with one being a positive terminal 1 and the other being a negative terminal (not shown).
  • the battery cells may be connected at their terminals by interconnectors such as wires 5 and the like to enable an electric current to flow between the electric cells.
  • the module 100 or module walls 120 may form a space having a volume.
  • the cells 10 may be positioned within the space to consume a portion of the volume.
  • the material such as a pottant 7 formed from the coating compositions disclosed herein may be positioned within the space to consume a portion of the volume such that the material is adjacent to a surface of a cell wall 13 and/or an interior surface of one or more of the walls 120 of the module 100.
  • FIG. 5 illustrates an exploded perspective view of a battery module 100 comprised of one or more arrays of battery cells 10, a cooling fin 230, and a cooling plate 240.
  • Materials such as pads 8 formed from the compositions disclosed herein in a cured state, may he positioned between cells 10. Additional pads 8 may be positioned between the cells 10, the cooling fin 230, the cooling plate 240, and/or an interior surface of walls 120. Other pads 8 may be positioned adjacent to an exterior surface of the walls 120.
  • FIG. 6 illustrates an isometric view of a battery cell 10 (FIG. 6A) to battery module 100 (FIG. 6B) to battery pack 200 (FIG. 6C) battery assembly.
  • the battery module 100 comprises a plurality of battery cells 10 and the battery pack 200 comprises a plurality of battery modules 100.
  • FIG. 7 illustrates a perspective view of a battery pack 200 cutout.
  • the battery pack 200 includes a plurality of battery modules 100 and cells 10 within each module 100.
  • the base of the battery pack 200 comprises a cooling plate 240.
  • Materials, such as adhesives 9 formed from the compositions disclosed herein in a cured state, may be positioned between the cooling plate 240 and interior surface of a wall of the battery pack 200.
  • Materials, such as pads 8 formed from the compositions disclosed herein in a cured state may be positioned between cells 10 within modules 100.
  • FIG. 8 illustrates an isometric view of a cell 10 to pack battery 200 assembly. Cells 10 are arranged within the pack 200 (without being in separate modules).
  • the battery cells may be arranged on or within an article such as, but not limited to, a cell to chassis battery assembly, as illustrated in FIG. 9, wherein one or more cells is used to construct the battery assembly without prior assembly of the cells into modules and/or packs.
  • FIG. 9 illustrates an isometric cut-out view of a cell to chassis battery assembly 300.
  • Cells 10 are arranged on a base comprising the undercarriage 55 and supported by the vehicle frame 45 and under the vehicle interior floor 35.
  • Any battery assembly may further comprise a thermal management system comprising air or fluid circuits which may be liquid based (for example glycol solutions) or direct refrigerant based.
  • a thermal management system comprising air or fluid circuits which may be liquid based (for example glycol solutions) or direct refrigerant based.
  • the substrate may comprise a coating formed from a hot melt formed by one of the compositions disclosed herein on a portion of a surface of the substrate that, in a cured state, has: (a) a lap shear strength of at least 15 MPa at 25 °C measured according to ASTM D1002-10 using 2024 T3 aluminum substrate of 0.063 inch thickness, as measured by an INSTON 5567 machine in tensile mode with a pull rate of 1.3 mm per minute; (b) a lap shear strength of at least 5 MPa at 50°C measured according to ASTM DI 002- 10 using 2024 T3 aluminum substrate of 0.063 inch thickness, as measured by an INSTON 5567 machine in tensile mode with a pull rate of 1.3 mm per minute; (c) a lap shear strength of no more than 2 MPa at 150°C measured according to ASTM D1002-10 using 2024 T3 aluminum substrate of 0.063 inch thickness, as measured by an INSTON 5567 machine in tensile mode with a
  • a composition comprising: a first component comprising a first compound comprising a furan functional group and an isocyanate functional group; a second component comprising a dienophile-containing compound; and a thermally expandable material.
  • composition of aspect 1, wherein the first compound comprises a urethane linkage, a urea linkage, and/or a thiourethane linkage.
  • composition of any of the preceding aspects wherein the first compound comprises Structure I: wherein X comprises O, N, or S, m > 1, n > 1, the sum of m+n > 2, Ri comprises a substituted or unsubstituted alkyl group, an alkylene group, a (cyclo)alkyl group, an aromatic group, an isocyanurate moiety, a biuret moiety, an allophonate moiety, a glycoluril moiety, a benzoguanamine moiety, an iminooxadiazinedione moiety, or a polymeric moiety different from the urethane linkage, the urea linkage, and/or the thiourethane linkage, and R2 comprises a substituted or unsubstituted alkyl group, an ester moiety, an ether moiety, or a urethane moiety.
  • composition of aspect 17, wherein the active hydrogen-containing functional group comprises a hydroxyl functional group, an amine functional group, and/or a mercapto functional group.
  • composition of aspect 17 or aspect 18, wherein the isocyanate functional group comprises an isocyanate functional group from the polyisocyanate.
  • composition of any of aspects 17 to 20, wherein the equivalence ratio of the active hydrogen-containing functional groups and the isocyanate functional group is less than 1:1, such as no more than 1:2, such as no more than 1:3, such as no more than 1:5.
  • composition of any of the preceding aspects, wherein the dienophile- containing compound comprises a dienophile equivalent weight of at least 100 g/eq, such as at least 200 g/eq.
  • composition of any of the preceding aspects, wherein the dienophile- containing compound comprises a dienophile equivalent weight of no more than 3,000 g/eq, such as no more than 1,000 g/eq.
  • composition of any of the preceding aspects, wherein the dienophile- containing compound comprises a dienophile equivalent weight of 100 g/eq to 3,000 g/eq, such as 200 g/eq to 1,000 g/eq.
  • composition of any of the preceding aspects, wherein the dienophile comprises a maleimide functional group, a maleate functional group, and/or a fumarate functional group.
  • composition of aspect 31, wherein the third compound comprises a hydroxyl functional group.
  • composition of aspect 32 comprising the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound at an equivalence ratio of at least 0.2:1, such as at least 0.4:1.
  • composition of aspect 32 or aspect 33 comprising the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound at an equivalence ratio of no more than 3:1, such as no more than 2:1.
  • composition of any of aspects 32 to 34 comprising the isocyanate functional group on the first compound and the hydroxyl functional group on the third compound at an equivalence ratio of 0.2:1 to 3:1, such as 0.4:1 to 2:1.
  • composition of aspect 36, wherein the fourth compound comprises a furan equivalent weight of at least 68 g/eq, such as at least 80 g/eq.
  • composition of aspect 36 or aspect 37, wherein the fourth compound comprises a furan equivalent weight of no more than 1,500 g/eq, such as no more than 1,000 g/eq.
  • the thermally expandable material is present in the first component, the second component, and/or a third component.
  • thermally expandable material comprises an average initial (pre-expansion) particle size of at least 0.5 pm measured by laser diffraction, such as at least 2 pm, such as at least 3 pm, such as at least 5 pm, such as at least 10 pm.
  • thermally expandable material comprises an average initial (pre-expansion) particle size of no more than 100 pm measured by laser diffraction, such as no more than 80 pm, such as no more than 60 pm, such as no more than 50 pm.
  • thermally expandable material comprises an average initial (pre-expansion) particle size of 0.5 pm to 100 pm measured by laser diffraction, such as 1 pm to 80 pm, such as 2 pm to 60 pm, such as 3 pm to 50 pm, such as 5 pm to 50 pm, such as 10 pm to 50 pm.
  • composition of any of the preceding aspects comprising the thermally expandable material in an amount of at least 0.5% by weight based on total weight of the composition, such as at least 0.75% by weight, such as at least 1% by weight.
  • composition of any of the preceding aspects comprising the thermally expandable material in an amount of no more than 10% by weight based on total weight of the composition, such as no more than 7% by weight, such as no more than 3% by weight.
  • composition of any of the preceding aspects comprising the thermally expandable material in an amount of 0.5% by weight to 10% by weight based on total weight of the composition, such as 0.75% by weight to 7% by weight, such as 1% by weight to 3% by weight.
  • composition of any of the preceding aspects further comprising a filler, an accelerator, a dispersant, an additive, and/or elastomeric particles.
  • composition of aspect 47 wherein the first component, the second component, and/or a third component comprises the filler, the accelerator, the dispersant, the additive, and/or the elastomeric particles.
  • composition of aspect 47 or aspect 48, wherein the composition comprises the filler in an amount of at least 0.5% by weight based on total weight of the composition, such as at least 1% by weight.
  • composition of aspect 52 comprising the thermally conductive filler in an amount of 100% by volume based on total volume of filler, such as no more than 90% by volume, such as no more than 80% by volume.
  • composition of aspect 52 or aspect 53 comprising the thermally conductive filler in an amount of at least 20% by volume based on total volume of filler, such as at least 50% by volume.
  • composition of any of aspects 52 to 54 comprising the thermally conductive filler in an amount of 20% by volume to 90% by volume based on total volume of filler, such as 50% by volume to 80% by volume.
  • composition of any of aspects 52 to 55 comprising the non-thermally conductive filler in an amount of at least 10% by volume based on total volume of filler, such as at least 20% by volume.
  • composition of any of aspects 52 to 56 comprising the non-thermally conductive filler in an amount of up to 100% by volume based on total volume of filler, such as no more than 80% by volume, such as no more than 50% by volume.
  • composition of any of aspects 52 to 57 comprising the non-thermally conductive filler in an amount of 10% by volume to 80% by volume based on total volume of filler, such as 20% by volume to 50% by volume.
  • composition of any of aspects 47 to 58 comprising the accelerator in an amount of at least 0.001% by weight based on total weight of the composition, such as at least 0.01% by weight.
  • composition of any of aspects 47 to 59 comprising the accelerator in an amount of no more than 2% by weight based on total weight of the composition, such as no more than 1 % by weight.
  • composition of any of aspects 47 to 60 comprising the accelerator in an amount of 0.001% by weight to 2% by weight based on total weight of the composition, such as 0.01% by weight to 1% by weight.
  • composition of any of aspects 47 to 61 comprising the dispersant in an amount of at least 0.5% by weight based on total weight of the composition, such as at least 1 % by weight.
  • composition of any of aspects 47 to 62 comprising the dispersant in an amount of no more than 10% by weight based on total weight of the composition, such as no more than 5% by weight.
  • composition of any of aspects 47 to 63 comprising the dispersant in an amount of 0.5% by weight to 10% by weight based on total weight of the composition, such as 1% by weight to 5% by weight.
  • composition of any of aspects 47 to 64 comprising the additive in an amount of at least 0.01% by weight based on total weight of the composition, such as at least 0.1% by weight.
  • composition of any of aspects 47 to 65 comprising the additive in an amount of no more than 15% by weight based on total weight of the composition, such as no more than 10% by weight.
  • composition of any of aspects 47 to 66 comprising the additive in an amount of 0.01% by weight to 15% by weight based on total weight of the composition, such as 0.1% by weight to 10% by weight.
  • composition of any of aspects 47 to 69 comprising the elastomeric particles in an amount of 0.1% by weight to 50% by weight based on total weight of the composition, such as 1% by weight to 20% by weight.
  • the filler comprises a thermally conductive filler such as boron nitride, aluminum trihydrate, and/or aluminum oxide and/or a non-thermally conductive filler such as fumed silica, wollastonite, calcium carbonate, micaceous iron oxide, or combinations thereof;
  • a thermally conductive filler such as boron nitride, aluminum trihydrate, and/or aluminum oxide and/or a non-thermally conductive filler such as fumed silica, wollastonite, calcium carbonate, micaceous iron oxide, or combinations thereof;
  • the additive comprises a rheology modifier, a tackifier, a thermoplastic polymer, a surfactant, a flame retardant, a corrosion inhibitor, a UV stabilizer, a colorant, a tint, a solvent, a plasticizer, an adhesion promoter, an antioxidant, a silane, a silane terminated polymer, a moisture scavenger, a thixotrope, and/or a sag control agent;
  • the elastomeric particles comprise a core-shell structure, such as comprising an acrylic shell and an elastomeric core;
  • the accelerator comprises an amine-based catalyst and/or an organometallic complex.
  • composition of any of the preceding aspects formulated as a two- component composition.
  • 150°C (measured using a TA Instruments Q800 DMA V21.3 in single cantilever mode), such as -120°C to 100°C.
  • a method of coating a substrate comprising: contacting a portion of a surface of the substrate with the composition of any of the preceding aspects; and optionally (i) curing the composition at a temperature lower than an expansion temperature of the expandable material and/or (ii) curing the composition prior to expansion of the thermally expandable material.
  • a substrate comprising a coating formed from the composition of any of aspects 1 to 78 on a portion of a surface of the substrate.
  • a substrate comprising a coating formed from the composition of any of aspects 1 to 78 on a portion of a surface of the substrate.
  • a battery comprising the battery cell of aspect 91, and optionally a battery component.
  • a vehicle comprising the battery of any of aspects 96 to 99.
  • a system comprising: a dielectric coating composition for application to a first portion of a surface of a substrate; and the composition of any of aspects 1 to 78 for application to a second portion of the surface.
  • a kit comprising: a dielectric coating composition for application to a first portion of a surface of a substrate; and the composition of any of aspects 1 to 78 for application to a second portion of the surface
  • the dielectric coating composition comprises: a binder comprising a film-forming resin such as a polyester, alkyl, urethane, isocyanate, polyurea, epoxy, acrylic, polyether, polysulfide, polyamine, polyamide, polyvinyl chloride, polyolefin, polyvinylidene fluoride, polyvinyl chloride, polyolefin, polysiloxane, aminealdehydes, resinous polyols, phosphatized polyepoxides, phosphatized acrylic polymers, aminoplasts, or combinations thereof; and/or a curing agent and/or crosslinker capable of crosslinking with the film-forming resin to cure the dielectric coating composition, such as an amine, aminoplast, phenoplast, polyisocyanate, including blocked isocyanate, polyepoxide, beta-hydroxyalkylamide, polyacid, organometallic acid-functional material,
  • a film-forming resin such as a polyester, alkyl, urethane
  • the dielectric coating composition comprises a powder coating composition and/or a liquid coating composition such as an electrodepositable coating composition, a UV-curable coating composition, and/or a solvent-based coating composition.
  • compositions I and II were prepared using the materials and quantities listed in Table 1 .
  • Desmodur N3900 an aliphatic polyisocyanate (hexamethylene diisocyanate trimer), was charged to an appropriately sized flask and blanketed with nitrogen to avoid interaction with moisture.
  • Dibutyltin dilaurate was added as a catalyst and this mixture was heated to 60°C. At 60°C, furfuryl alcohol was then added at a rate such that the temperature of the solution did not exceed 80°C.
  • compositions III and IV in Table 2 were used to prepare Compositions III and IV in Table 2.
  • Compositions V to VIII were all prepared with the materials listed in Table 2 in a 200 max DAC cup using FlackTek Speedmixer. Wet components were all added to the DAC cup and mixed for 2 minutes at 2350 RPM. Dry components were then added and mixed for an additional 2 minutes at 2350 RPM.
  • a deoxidizing composition (DEOX-1) was prepared with 18.2 liters of deionized water, 180.5 g fluorosilicic acid (23% solution), 80 g fluorozirconic acid (45% solution), 11.61 g potassium bifluoride, and 31.6 g of Chemfil Buffer (commercially available from PPG Industries, Inc.). Compositions III to VIII were then used to prepare tested Compositions IX to XIV. Compositions IX to XIV were each prepared in a 60 max DAC cup as separate parts A and B using the materials listed in Table 3. Wet components were all added and mixed for 2 minutes at 2350 RPM using a Dual- Asymmetric Mixer (SpeedMixer®).
  • Lap shear specimens were prepared using 0.063” 2024 T3 Aluminum. The panels were cleaned of all oils with acetone and methylethyl ketone and treated with DEOX- 1. These panels were then coated with a primer layer by drawing down the one-component epoxy adhesive composition PR-2930® (commercially available from PPG Industries) PR-2 at 0.010” thickness and baking at 180°C for 30 minutes. Lap Shear- Specimens (LSS) were tested using Instron Model 5567 with 30 kN load cell.
  • test samples were 1” x 2”, and the test rate for all three temperatures was 1.3 mm/minute.
  • Lap shear specimens were prepared by applying the adhesive to one side of the primed substrate, and the two pieces were overlapped at i” and held together using binder clips, then excess adhesive was removed from the joint using a metal spatula. These samples were then cured at 50°C for 24 hours. After curing, the samples cooled for 1 hour to room temperature.
  • each sample was measured pre- and post-expansion using a caliper, then used to calculate the volume expansion ratio. Thermal expansions were performed in an oven preheated to 160°C. Each sample was thermally expanded with a weight atop to exert a pressure of 3.2 kPa. Thermal conductivity of each sample was measured pre- and post-expansion using a TCi Thermal Conductivity Analyzer (commercially available from C- Therm Technologies Ltd.). Thermal conductivity samples were prepared via casting a sample into a mold to obtain a sample with at least 30 mm in diameter and 5 mm in height and allowing the composition to cure as described above.
  • Coatings formed from Compositions IX and X also surprisingly exhibited an ability to expand at a ratio even greater than coatings formed from Compositions XIII and XIV upon thermal activation. Coatings formed from Compositions XI and XII demonstrated similar strengths to coatings formed from Compositions IX and X, but did not expand. The thermal conductivity of the coating formed from Composition X dropped from 1.23 W/mK to 0.38 W/mK after thermal activation and expansion, demonstrating that the coating formed from the composition went from thermally conductivity to thermally insulative following expansion.
  • DESMODUR N3900 is commercially available from Covestro.
  • Dibutyl tin dilaurate is commercially available from Evonik Industries.
  • Part #1 was added to a 2000-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, a nitrogen blanket, and a heating mantle with a thermometer connected through a temperature feedback control device. The reaction mixture was heated to 60°C. Then part #2 was added at a rate such that the temperature of the mixture did not exceed 80°C. After part #2 was added, the reaction was held at 80°C until the isocyanate equivalent weight was stalled. The isocyanate equivalent weight was determined by titration of a sample.
  • the sample was prepared by dissolving 1 g of the isocyanate per 420 g/eq of predicted isocyanate equivalent weight in 30 mL of a solution comprising 20 mL of dibutylamine and 980 mL of N-methyl-2-pyrrolidone. The sample was then titrated with 0.2 N HC1 solution in isopropanol titration agent using a Metrohm 808 or 888 Titrando. The reaction mixture was maintained at 80°C until the isocyanate equivalent weight was stalled. Then the reaction mixture was poured out at 40°C with a N2 blanket.
  • Example C describes the synthesis of an alternative dienophile prepolymer.
  • Dipropylene glycol is commercially available from Sigma Aldrich.
  • Monobutyltin oxide is commercially available from ARKEMA INC.
  • Part #1 was added to a 1000-mililiter, 4-necked round flask equipped with a motor driven stainless steel stir blade, a water-cooled condenser, and a heating mantle with a thermometer connected through a temperature feedback control device. The mixture was heated to 220°C and held until the acid value was stalled around 150 mg KOH/g by titration. Then the mixture was cooled to 120°C and Pail #2 was added. The mixture was heated to 140°C and held until the acid value was less than 2 mg KOH/g by titration.
  • the mixture was then cooled to 80°C and poured into an appropriately sized container.
  • the final OH equivalent weight was 302 g/eq, determined by titration.
  • the hydroxyl number was determined by esterification of the same with excess acetic anhydride at elevated temperatures using imidazole as a catalyst.
  • the excess acetic anhydride was converted to acetic acid by hydrolysis and titrated potentiometrically with standard potassium hydroxide.
  • DEOX-1 was prepared as described above.
  • Compositions XV and XVI were formed by blending the components in Table 6 at the ratios described and mixed for 4 minutes at 2350 RPM using a Dual-Asymmetric Mixer (SpeedMixer®).
  • Lap shear specimens (dimensions of 25.6 mm x 12.8 mm) were prepared using 0.063” 2024 T3 Aluminum. The panels were cleaned of oils with acetone and methyl-ethyl ketone and treated with DEOX-1.
  • Lap shear specimens were prepared by applying Composition XV or Composition XVI to one side of a primed panel, then overlapping with a second panel (overlap dimensions 1” x V2”).
  • compositions according to the present disclosure demonstrate comparable lap shear strength while also debonding when exposed to high temperatures.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

L'invention concerne des compositions comprenant : un premier composant comprenant un premier composé comprenant un groupe fonctionnel furane et un groupe fonctionnel isocyanate ; un second composant comprenant un composé contenant du diénophile ; et un matériau thermiquement expansible. L'invention concerne également des procédés de revêtement d'un substrat comprenant la mise en contact d'une partie d'une surface du substrat avec l'une quelconque des compositions de l'invention. L'invention concerne également des procédés de formation d'un article comprenant l'extrusion de l'une quelconque des compositions de l'invention. L'invention concerne également des substrats comprenant un revêtement formé à partir de l'une quelconque des compositions de l'invention sur une partie d'une surface du substrat.
PCT/US2024/058198 2024-02-26 2024-12-03 Compositions contenant des composés fonctionnels furane et fonctionnels isocyanate et matériau expansible Pending WO2025183770A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202463557854P 2024-02-26 2024-02-26
US63/557,854 2024-02-26
US202463691201P 2024-09-05 2024-09-05
US63/691,201 2024-09-05

Publications (1)

Publication Number Publication Date
WO2025183770A1 true WO2025183770A1 (fr) 2025-09-04

Family

ID=94083610

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2024/058198 Pending WO2025183770A1 (fr) 2024-02-26 2024-12-03 Compositions contenant des composés fonctionnels furane et fonctionnels isocyanate et matériau expansible

Country Status (1)

Country Link
WO (1) WO2025183770A1 (fr)

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793867A (en) 1986-09-26 1988-12-27 Chemfil Corporation Phosphate coating composition and method of applying a zinc-nickel phosphate coating
US5588989A (en) 1994-11-23 1996-12-31 Ppg Industries, Inc. Zinc phosphate coating compositions containing oxime accelerators
US7749368B2 (en) 2006-12-13 2010-07-06 Ppg Industries Ohio, Inc. Methods for coating a metal substrate and related coated substrates
US20120129980A1 (en) 2010-11-19 2012-05-24 Ppg Industries Ohio, Inc. Structural adhesive compositions
US8673091B2 (en) 2007-08-03 2014-03-18 Ppg Industries Ohio, Inc Pretreatment compositions and methods for coating a metal substrate
US9562175B2 (en) 2010-11-19 2017-02-07 Ppg Industries Ohio, Inc. Adhesive compositions containing graphenic carbon particles
CN111040110A (zh) * 2019-01-01 2020-04-21 翁秋梅 一种力致响应动态聚合物及其应用
CN111040202A (zh) * 2019-01-01 2020-04-21 翁秋梅 一种组合杂化动态聚合物及其应用
WO2021173941A1 (fr) 2020-02-26 2021-09-02 Ppg Industries Ohio, Inc. Compositions de revêtement en poudre thermiquement conductrices et électriquement isolantes
US11820926B1 (en) * 2020-10-27 2023-11-21 Geisys Ventures, LLC Programmable adhesive based upon Diels-Alder chemistry

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793867A (en) 1986-09-26 1988-12-27 Chemfil Corporation Phosphate coating composition and method of applying a zinc-nickel phosphate coating
US5588989A (en) 1994-11-23 1996-12-31 Ppg Industries, Inc. Zinc phosphate coating compositions containing oxime accelerators
US7749368B2 (en) 2006-12-13 2010-07-06 Ppg Industries Ohio, Inc. Methods for coating a metal substrate and related coated substrates
US8673091B2 (en) 2007-08-03 2014-03-18 Ppg Industries Ohio, Inc Pretreatment compositions and methods for coating a metal substrate
US20120129980A1 (en) 2010-11-19 2012-05-24 Ppg Industries Ohio, Inc. Structural adhesive compositions
US9562175B2 (en) 2010-11-19 2017-02-07 Ppg Industries Ohio, Inc. Adhesive compositions containing graphenic carbon particles
CN111040110A (zh) * 2019-01-01 2020-04-21 翁秋梅 一种力致响应动态聚合物及其应用
CN111040202A (zh) * 2019-01-01 2020-04-21 翁秋梅 一种组合杂化动态聚合物及其应用
WO2021173941A1 (fr) 2020-02-26 2021-09-02 Ppg Industries Ohio, Inc. Compositions de revêtement en poudre thermiquement conductrices et électriquement isolantes
US11820926B1 (en) * 2020-10-27 2023-11-21 Geisys Ventures, LLC Programmable adhesive based upon Diels-Alder chemistry

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Glossary of basic terms in polymer science (IUPAC Recommendations 1996).", PURE AND APPLIED CHEMISTRY, vol. 68, no. 2287, 1996, pages 2289

Similar Documents

Publication Publication Date Title
AU2021225930B2 (en) Thermally conductive and electrically insulating powder coating compositions
US20250304762A1 (en) Compositions containing thermally conductive fillers
EP4136139B1 (fr) Utilisation d'un revêtement formé à partir d'une composition contenant des charges thermoconductrices pour conférer une protection thermique et une protection contre l'incendie à un support
US20250171656A1 (en) Coating compositions
KR20220143746A (ko) 2-층 유전체 코팅
AU2021254760A1 (en) Compositions containing thermally conductive fillers
WO2025183770A1 (fr) Compositions contenant des composés fonctionnels furane et fonctionnels isocyanate et matériau expansible
WO2025183769A1 (fr) Composés à fonction furane et à fonction isocyanate et compositions à durcissement réversible
WO2025183771A1 (fr) Compositions contenant une charge thermoconductrice et un matériau thermiquement expansible
US20250340693A1 (en) Coating compositions
WO2021211185A1 (fr) Compositions contenant des charges thermoconductrices
WO2025188361A2 (fr) Compositions durcissables
WO2024044576A1 (fr) Compositions de revêtement
WO2024248935A1 (fr) Compositions contenant une charge thermoconductrice et un matériau thermiquement expansible
WO2025183772A1 (fr) Compositions contenant une charge thermoconductrice et un matériau thermiquement expansible
WO2024144922A2 (fr) Compositions durcissables
CN120677209A (zh) 阻燃粉末涂料
EP4665803A1 (fr) Revêtements en poudre ignifuges

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24828622

Country of ref document: EP

Kind code of ref document: A1