Antimicrobial coating for building panel

Patent metadata

Field	Value
Publication number	US-11122806-B2
Application number	US-201916656828-A
Country	US
Kind code	B2
Filing date	Oct 18, 2019
Priority date	Oct 19, 2018
Publication date	Sep 21, 2021
Grant date	Sep 21, 2021

Abstract

In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

First claim

What is claimed is:

1. A gypsum board comprising:
a gypsum core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide comprising at least one of an azole, a strobilurin, a fludioxonil, an isothiazolinone, a pyrithione, or a mixture thereof, at least one polymeric binder, and at least one pigment,
wherein the board exhibits at least a Level 3 finish, and
wherein the board satisfies at least one of the following:
the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.

2. The gypsum board of claim 1 , wherein the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 and a rating of at least 8 when tested in accordance to ASTM D3273-16.

3. The gypsum board of claim 1 , wherein the board exhibits a Level 5 finish.

4. The gypsum board of claim 1 , wherein the board exhibits an abrasion rating of at least 2 when tested in accordance to ASTM C1629/C1629M-15.

5. The gypsum board of claim 1 , wherein the at least one fungicide includes an azole, a strobilurin, a fludioxonil, or a mixture thereof.

6. The gypsum board of claim 1 , wherein the coating includes at least three fungicides.

7. The gypsum board of claim 6 , wherein the at least three fungicides include a mixture of thiabendazole, azoxystrobin, and fludioxonil.

8. The gypsum board of claim 1 , wherein the fungicides are present in the coating in an amount of from 1 ppm to 10,000 ppm.

9. The gypsum board of claim 1 , wherein the pigment comprises a white pigment.

10. The gypsum board of claim 9 , wherein the pigment comprises calcium carbonate, magnesium carbonate, or a mixture thereof.

11. The gypsum board of claim 10 , wherein the pigment further comprises a titanium dioxide.

12. The gypsum board of claim 1 , wherein the pigment has a brightness of at least 90% as determined in accordance to T534 om-76 and/or a median size of from 0.1 microns to 5 microns.

13. The gypsum board of claim 1 , wherein the polymeric binder comprises a vinyl acetate polymer or copolymer, an acrylic polymer or copolymer, a styrene polymer or copolymer, a vinyl acrylic polymer or copolymer, a cellulose, a starch, or a mixture thereof.

14. The gypsum board of claim 1 , wherein the polymeric binder comprises an acrylic polymer or copolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, a vinyl acrylic copolymer, or a mixture thereof.

15. The gypsum board of claim 1 , wherein the polymeric binder comprises a mixture of an acrylic polymer or copolymer, a styrene butadiene copolymer, and a cellulose.

16. The gypsum board of claim 1 , wherein the coating comprises a surfactant.

17. The gypsum board of claim 1 , wherein the coating comprises a wax.

18. The gypsum board of claim 17 , wherein the wax comprises a polyolefin wax.

19. The gypsum board of claim 1 , wherein the facing material comprises a paper.

20. The gypsum board of claim 1 , wherein the facing material comprises a glass mat.

21. A method of making the gypsum board of claim 1 , the method comprising:
providing a first facing material,
depositing a gypsum slurry onto the first facing material,
providing a second facing material onto the gypsum slurry, and
wherein at least one of the first facing material and the second facing material includes a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment.

22. The method of claim 21 , wherein the coating is applied to the first facing material prior to depositing the gypsum slurry.

23. The method of claim 21 , wherein the coating is applied to the second facing material prior to providing on top of the gypsum slurry.

24. A building panel comprising:
a cementitious core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide comprising an azole, a strobilurin, a fludioxonil, or a mixture thereof, at least one polymeric binder, and at least one pigment, and
wherein the panel satisfies at least one of the following:
the panel exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the panel exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.

25. A gypsum board comprising:
a gypsum core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder comprising an acrylic polymer or copolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, a vinyl acrylic copolymer, or a mixture thereof, and at least one pigment,
wherein the board exhibits at least a Level 3 finish, and
wherein the board satisfies at least one of the following:
the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.

26. The gypsum board of claim 25 , wherein the polymeric binder comprises a mixture of an acrylic polymer or copolymer and a styrene butadiene copolymer and further comprises a cellulose.

Assignees

• Nat Gypsum Properties Llc
• Gold Bond Building Products Llc

Inventors

• Wilson Thomas R
• Bailey Joseph J

Classifications

• C04B26/04 Primary

  obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• C04B26/285

  Cellulose or derivatives thereof (C04B26/24 takes precedence) · CPC title

• C04B26/28

  Polysaccharides or derivatives thereof · CPC title

• A01N43/78 Primary

  1,3-Thiazoles; Hydrogenated 1,3-thiazoles · CPC title

• A01N25/34

  Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group · CPC title