Two-layer dielectric coating

1 . A coated substrate comprising a first coating layer comprising:

an electrodepositable coating layer deposited from an electrodepositable coating composition, and

a second coating layer comprising a powder coating layer on at least a portion of the first coating layer, wherein the powder coating layer is formed from a powder coating composition, and wherein the first coating layer and second coating layer form a multi-layer dielectric coating having a dielectric strength of at least 1 kV, as measured by a Sefelec Dielectrimeter RMG12AC-DC and in accordance with ASTM D 149-09 Hipot test; and

wherein the substrate comprises a battery or a battery component, wherein the battery component comprises a battery cell, a battery shell, a battery module, a battery pack, a battery box, a battery cell casing, a pack shell, a battery lid and tray, a thermal management system, an inverter, a battery housing, a module house, a module racking, a battery side plate, a battery cell enclosure, a cooling module, a cooling tube, a cooling fin, a cooling plate, a bus bar, a battery frame, and/or a stationary energy storage system.

2 . The coated substrate of claim 1 , wherein the powder coating composition comprises a binder comprising a film-forming resin comprising an epoxy resin.

3 . The coated substrate of claim 1 , wherein the powder coating composition comprises a binder comprising a film-forming resin comprising an epoxy resin and a polyester resin.

4 . The coated substrate of claim 1 , wherein the powder coating composition comprises a binder comprising a crosslinker, and wherein the crosslinker comprises a phenolic resin, an amino resin, an epoxy resin, a triglycidyl isocyanurate, a beta-hydroxy (alkyl)amide, an alkylated carbamate, a (meth)acrylate, a salt of a polycarboxylic acid with cyclic amidine, o-tolyl biguanide, an isocyanate, a blocked isocyanate, a polyacid, an anhydride, an organometallic acid-functional material, a polyamine, a polyamide, an aminoplast, a carbodiimide, an oxazoline, and/or combinations thereof.

5 . The coated substrate of claim 1 , wherein the powder coating composition comprises a binder comprising: (a) an epoxy functional polymer; (b) a poly-carboxylic acid functional polyester polymer reactive with the epoxy functional polymer and which comprises an acid value of less than 100 mg KOH/g; and (c) a poly-carboxylic acid functional (meth)acrylate polymer reactive with the epoxy functional polymer.

6 . The coated substrate of claim 1 , wherein the powder coating composition further comprises a thermally conductive, electrically insulative filler material.

7 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises boron nitride, silicon nitride, aluminum nitride, boron arsenide, aluminum oxide, magnesium oxide, dead burn magnesium oxide, beryllium oxide, silicon dioxide, titanium oxide, zinc oxide, nickel oxide, copper oxide, tin oxide, aluminum hydroxide, magnesium hydroxide, boron arsenide, silicon carbide, agate, emery, ceramic microspheres, diamond, or any combination thereof.

8 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises aluminum hydroxide present in an amount of at least 40% by weight, based on the total weight of the powder coating composition.

9 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises dead burned magnesium oxide.

10 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises aluminum hydroxide and dead burned magnesium oxide.

11 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises boron nitride present in an amount of greater than 40% and less than 50% by weight, based on the total weight of the powder coating composition.

12 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises at least two of aluminum hydroxide, dead burned magnesium oxide, and boron nitride.

13 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises aluminum hydroxide and/or boron nitride present in a combined amount of at least 40% by weight, and the total amount of boron nitride present is less than 50% by weight, the % by weight based on the total weight of the powder coating composition.

14 . The coated substrate of claim 6 , wherein the thermally conductive, electrically insulative filler material comprises dead burned magnesium oxide and boron nitride.

15 . The coated substrate of claim 6 , wherein the powder coating composition further comprises a thermoplastic material and/or a core-shell polymer.

16 . The coated substrate of claim 1 , wherein the electrodepositable coating composition comprises a phyllosilicate pigment and/or a fluoropolymer.

17 . A method of making the coated substrate of claim 1 , composition coating the substrate comprising electrodepositing the electrodepositable coating layer deposited from an electrodepositable coating composition onto a surface of the substrate and applying the powder coating layer on to at least a portion of the electrodepositable coating layer.

18 . The coated substrate of claim 1 , wherein the electrodepositable coating composition comprises a thermally conductive, electrically insulative filler material.

19 . The coated substrate of claim 1 , wherein the dry film thickness of the multi-layer coating is at least 3 mils (76.2 microns).

20 . The coated substrate of claim 1 , wherein the dry film thickness of the multi-layer coating is 3 mils to 5 mils (76.2 microns to 127 microns).