Flame retardant clear coatings for building panels

Patent metadata

Field	Value
Publication number	US-12410610-B2
Application number	US-202217665813-A
Country	US
Kind code	B2
Filing date	Feb 7, 2022
Priority date	May 31, 2017
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

The present invention is directed to a flame retardant coating, the flame retardant coating comprising aluminum carbonate, triethanolamine, and a blend of a borate compound and a phosphate compound. The coating is optically transparent.

First claim

What is claimed is:

1. A flame-retardant coating composition comprising:
a coating comprising a first sub-layer, a second sub-layer atop the first sub-layer, and a third sub-layer atop the second sub-layer;
wherein the first sub-layer is an organic coating and comprises polymer produced from unsaturated monomers and the second sub-layer is an inorganic coating comprising aluminum carbonate, triethanolamine, and a blend of a first borate compound and a first phosphate compound;
wherein the aluminum carbonate is present in an amount of about 2.8 to about 4.8 wt. %;
wherein a weight ratio of first phosphate compound to the first borate compound within the second sub-layer is from about 5:1 to about 80:1;
wherein the third sub-layer is an inorganic coating composition comprising triethanolamine, a second borate compound, and a second phosphate compound; and
wherein the second borate compound is zinc borate and the first borate compound is boron trioxide.

2. The flame-retardant coating of claim 1 , wherein the flame-retardant coating composition is optically transparent.

3. The flame-retardant coating of claim 1 , wherein the inorganic coating has a maximum pH of about 5.

4. The flame-retardant coating of claim 1 , wherein the inorganic coating comprises up to about 5 wt. % of organic components based on the total weight of the inorganic coating.

5. The flame-retardant coating of claim 1 , wherein the first borate compound is present in an amount of about 0.5 wt. % to about 15.0 wt. %, based on the total dry weight of the second sub-layer.

6. The flame-retardant coating of claim 1 , wherein the first sub-layer comprises an organic component selected from the group consisting of a wax emulsion, latex polymer, and combinations thereof.

7. The flame-retardant coating of claim 1 , wherein the second sub-layer and the third sub-layer comprise calcium carbonate.

8. The composition of claim 1 , wherein the first phosphate compound is present in an amount from about 55.0 wt. % to about 75.0 wt. %, based on the total weight of the second sub-layer in the dry-state, and wherein the first borate compound is present in an amount of about 1 wt. % to about 10.5 wt. %, based on the total weight of the second sub-layer in the dry-state.

9. The composition of claim 1 , further comprising silicon dioxide.

10. A flame-retardant coating composition comprising:
a coating comprising a first sub-layer, a second sub-layer atop the first sub-layer, and a third sub-layer atop the second sub-layer;
wherein the second sub-layer comprises an inorganic component comprising aluminum carbonate, triethanolamine, a filler comprising magnesium carbonate and calcium carbonate, and a blend of a first borate compound and a first phosphate compound comprising phosphoric acid;
wherein the third sub-layer comprises a second inorganic component comprising triethanolamine, magnesium carbonate, and a blend of a second borate compound that is different from the first borate compound and a second phosphate compound;
wherein the aluminum carbonate is present in an amount from about 2.8 to about 4.8 wt. %;
wherein the coating composition has a maximum pH of 5 and comprises up to about 5.0 wt. % of organic components based on the total weight of the coating composition;
wherein the composition is free of carrier;
wherein the first borate compound is boron trioxide and the second borate compound is zinc borate;
wherein a weight ratio of phosphate to the borate compound within the inorganic component of the second sub-layer is from about 5:1 to about 80:1;
wherein the flame-retardant coating composition is optically transparent.

11. The composition of claim 10 , wherein the triethanolamine is present in an amount ranging from a non-zero amount to less than 5.0 wt. %, based on the total weight of the coating composition.

12. The composition of claim 10 , wherein the composition comprises up to about 1.0 wt. % of organic components, based on the total weight of the coating composition.

13. The composition of claim 10 , wherein the first phosphate compound is present in an amount from about 55.0 wt. % to about 75.0 wt. %, based on the total weight of the coating composition, and wherein the first borate compound is present in an amount of about 1 wt. % to about 10.5 wt. %, based on the total weight of the coating composition.

14. The composition of claim 10 , further comprising silicon dioxide.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Hughes John E
• Wang Michelle X

Classifications

• E04B9/16

  the members lying in different planes · CPC title

• E04B9/366

  the principal plane of the slats being vertical · CPC title

• B32B21/00

  Layered products comprising {a layer of} wood, e.g. wood board, veneer, wood particle board · CPC title

• E04C2/08

  of metal, e.g. sheet metal (E04C2/26 takes precedence) · CPC title

• E04B9/045

  being laminated · CPC title