Formulation for a fibrous non-woven facing material

Patent metadata

Field	Value
Publication number	US-12378729-B2
Application number	US-202017609936-A
Country	US
Kind code	B2
Filing date	May 7, 2020
Priority date	May 10, 2019
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

The present invention provides a formulation for a fibrous non-woven facing material, wherein the formulation comprises a binder, a filler, and an extender. The extender has an median particle size, d 50 , which is equal to or less than 3.5 μm, and a non-spherical morphology. The filler has an median particle size, d 50 , which is equal to or less than 3.0 μm and wherein the filler has a d 10 equal to or less than 1.0 μm and a d 90 equal to or less than 6.0 μm. The formulation comprises less than 13 wt % titanium dioxide on a dry solids basis. Also provided is a fibrous non-woven facing material comprising the formulation, a process for preparing the fibrous non-woven facing material and a fibrous non-woven facing material obtained by said process.

First claim

The invention claimed is:

1. A formulation for a fibrous non-woven facing material, wherein the formulation comprises:
(i) a binder;
(ii) a filler; and
(iii) an extender;
wherein a median particle size, d 50 , of the extender is equal to or less than 3.5 μm, and wherein the extender has a non-spherical morphology;
wherein a median particle size, d 50 , of the filler is equal to or less than 3.0 μm and wherein the filler has a d 10 equal to or less than 1.0 μm and a d 90 equal to or less than 6.0 μm;
wherein a weight ratio based on dry solids of the binder to a sum of the extender and the filler is from 0.05:1 to 7:2;
wherein a weight ratio based on dry solids of the extender to the filler is from 0.05:1 to 18:1;
wherein the formulation comprises less than 13 wt % titanium dioxide on a dry solids basis;
wherein the formulation has a total solids content of from 30 to 85%; and
wherein the formulation is free of a pigment having a refractive index of 2.5 or more.

2. The formulation according to claim 1 , wherein the extender has a non-spherical morphology consisting essentially of plate-shaped particles, rod-shaped particles, cubic or cuboid-shaped particles, pseudo-cubic shaped particles or cigar-shaped particles.

3. The formulation according to claim 1 , wherein the extender comprises kaolin, calcium carbonate, Huntite, magnesium carbonate, calcium-magnesium carbonate, or a mixture thereof.

4. The formulation according to claim 1 , wherein the filler comprises calcium carbonate or aluminium trihydrate.

5. The formulation according to claim 1 , wherein the filler has a refractive index of less than 2.5.

6. The formulation according to claim 1 , wherein the extender has a refractive index of less than 2.5.

7. The formulation according to claim 1 , wherein the median particle size, d 50 , of the extender is equal to or less than 3.5 μm and greater than 0.6 μm.

8. The formulation according to claim 1 , wherein the average particle size, d 90 , of the extender is between 4 and 20 μm.

9. The formulation according to claim 1 , wherein the median particle size, d 50 , of the filler is equal to or less than 0.8 μm.

10. The formulation according to claim 1 , wherein the filler has a d 50 equal to or less than 1.5 μm, a d 10 equal to or less than 0.5 μm and a d 90 equal to or less than 5 μm and wherein the filler comprises calcium carbonate, kaolin, magnesium carbonate, or a mixture thereof.

11. The formulation according to claim 1 , wherein the filler has a d 50 equal to or less than 2.5 μm, a d 10 equal to or less than 0.9 μm and a d 90 equal to or less than 6.0 μm, and wherein the filler comprises aluminium trihydrate.

12. The formulation according to claim 1 , wherein the formulation comprises less than 10 wt % of titanium dioxide, on a dry solids basis.

13. The formulation according to claim 1 , wherein the formulation is substantially free of titanium dioxide.

14. The formulation according to claim 1 , wherein the binder comprises from 5 wt % to 35 wt % of the dry solids of the formulation.

15. The formulation according to claim 1 , wherein the extender comprises from 5 wt % to 90 wt % of the dry solids of the formulation.

16. The formulation according to claim 1 , wherein the filler comprises from 5 wt % to 90 wt % of the dry solids of the formulation.

17. The formulation according to claim 1 , wherein a weight ratio based on dry solids of the binder to the extender is from 0.05:1 to 7:1.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Khandelwal Hitesh
• Lacamera Domenico
• Geel Paul
• Ritterbex Joshua

Classifications

• D21H27/20

  Flexible structures being applied by the user, e.g. wallpaper (printed wallpapers B41M3/18; paperhanging B44C7/00; pregummed wallpaper C09J7/21) · CPC title

• D21H21/28

  Colorants {; Pigments or opacifying agents} · CPC title

• D21H17/68

  siliceous, e.g. clays · CPC title

• D21H17/675

  Oxides, hydroxides or carbonates · CPC title

• D21H17/20

  Macromolecular organic compounds · CPC title