High solids color face and edge coatings for building panels

Patent metadata

Field	Value
Publication number	US-12546111-B2
Application number	US-202318108597-A
Country	US
Kind code	B2
Filing date	Feb 11, 2023
Priority date	Jul 12, 2016
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

Described herein is a coated building panel having a body and a surface coating atop the body, the surface coating comprising inorganic pigment and a polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone; wherein the surface coating comprises a liquid carrier in an amount less than about 1 wt. % based on the total weight of the surface coating.

First claim

What is claimed is:

1 . A coated building panel comprising:
a body comprising an upper surface opposite a lower surface and a side surface extending between the upper surface and the lower surface; a surface coating atop the upper surface, the surface coating comprising:
inorganic pigment;
a binder comprising carboxylated polyvinyl acetate homopolymer; and
an anionic polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone;
wherein anionic groups are located on the terminal ends of the pendant side-chains; and wherein the surface coating comprises a liquid carrier in an amount less than about 1 wt. % based on the total weight of the surface coating.

2 . The coated building panel according to claim 1 , wherein the polymeric dispersant comprises a hydrophobic portion and a hydrophilic portion.

3 . The coated building panel according to claim 1 , wherein the polymeric dispersant has a molecular weight of at least 1,000 Mn.

4 . The coated building panel according to claim 1 , wherein the polymeric dispersant is present in an amount ranging from about 0.05 wt. % to about 2.0 wt. % based on the total weight of the surface coating.

5 . The coated building panel according to claim 1 , wherein the inorganic pigment has a particle size ranging from about 15 nm to about 1,000 μm.

6 . The coating building panel according to claim 5 , wherein the inorganic pigment has a maximum particle size of about 500 nm.

7 . The coated building panel according to claim 1 , wherein the surface coating is present in an amount ranging from about 10 g/m 2 to about 132 g/m 2 .

8 . The coated building panel according to claim 1 , wherein the inorganic pigment is present in an amount ranging from about 70 wt. % to about 95 wt. % based on the total weight of the surface coating.

9 . The coated building panel according to claim 1 , wherein the binder has a glass transition temperature greater than about 21° C.

10 . The coated building panel according to claim 1 , wherein the binder is present in an amount ranging from about 5 wt. % to about 20 wt. % based on the total weight of the surface coating.

11 . The coated building panel according to claim 1 , wherein the anionic polyacrylic polymer comprises a salt group formed from a neutralization of an acid group with a compound forming a cation.

12 . A coated building panel comprising:
a body comprising an upper surface opposite a lower surface and a side surface extending between the upper surface and the lower surface; a surface coating atop the upper surface, the surface coating comprising:
about 70 wt. % to about 95 wt. % of a pigment blend based on the total weight of the surface coating, the pigment blend comprising two or more inorganic pigments having a particle size ranging from 15 nm to 500 nm;
a binder comprising carboxylated polyvinyl acetate homopolymer; and
an anionic polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone;
wherein anionic groups are located on the terminal ends of the pendant side-chains; wherein the anionic polymeric dispersant comprises a hydrophobic portion and a hydrophilic portion; wherein the pigment blend comprises calcium carbonate and calcined diatomaceous earth; and wherein the surface coating comprises less than 1 wt. % of a liquid carrier based on the total weight of the surface coating.

13 . The coated building panel according to claim 12 , wherein the anionic polyacrylic dispersant comprises a salt group formed from a neutralization of an acid group with a compound forming a cation.

14 . The coated building panel according to claim 12 , further comprising a thickener.

15 . The coated building panel according to claim 14 , wherein the thickener comprises hydroxyethylcellulose.

16 . The coated building panel according to claim 12 , wherein the pigment blend comprises a first pigment, a second pigment that is different than the first pigment, and a third pigment that is different than the first pigment and the second pigment.

17 . The coated building panel according to claim 12 , wherein the pigment blend comprises kaolin.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Lu Lida
• Caldwell Kenneth G
• Wang Michelle X
• Hughes John E

Classifications

• C09D201/02

  characterised by the presence of specified groups {, e.g. terminal or pendant functional groups} · CPC title

• B32B2607/00

  Walls, panels · CPC title

• E04C2/246 Primary

  combinations of materials fully covered by E04C2/16 and E04C2/20 · CPC title

• C09D7/61

  inorganic · CPC title

• C09D7/66

  characterised by particle size · CPC title