Flame retardant clear coatings for building panels

Patent metadata

Field	Value
Publication number	US-12559936-B2
Application number	US-202318211031-A
Country	US
Kind code	B2
Filing date	Jun 16, 2023
Priority date	Nov 3, 2017
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

The present invention is directed to a flame-retardant building panel comprising a body having a first major surface opposite a second major surface, an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes a phosphate compound, and a metal complexing agent. In other aspect, the invention is a method of forming a flame-retardant building panel comprising: a) applying an inorganic coating composition to a major surface of a body; and b) drying the inorganic coating composition at an elevated temperature.

First claim

What is claimed is:

1 . A flame-retardant building panel comprising:
a body comprising a cellulosic layer, the body having a first major surface opposite a second major surface, and the first major surface of the body comprising the cellulosic layer; an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes:
a phosphate compound;
a borate compound comprising boron trioxide;
a filler comprising calcium carbonate, aluminum carbonate, magnesium carbonate, and fumed silica;
a cross-linker comprising triethanolamine; and
a metal complexing agent;
wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1; and wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.

2 . The flame-retardant building panel according to claim 1 wherein the cellulosic material is wood.

3 . The flame-retardant building panel according to claim 1 wherein the inorganic coating is glass-forming.

4 . The flame-retardant building panel according to claim 1 wherein the inorganic coating has a solids content of at least 99% based on the total weight of the inorganic coating.

5 . The flame-retardant building panel according to claim 1 wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 75:1 to about 150:1.

6 . The flame-retardant building panel according to claim 1 wherein the inorganic coating has a thickness ranging from about 0.5 mils to about 5.0 mils.

7 . The flame-retardant building panel according to claim 1 wherein the metal ion is iron and a weight ratio of the phosphate compound to the metal ion is at least about 20,000:1.

8 . A flame-retardant building panel comprising:
a body comprising a cellulosic layer, the body having a first major surface opposite a second major surface, and the first major surface of the body comprising the cellulosic layer; an inorganic coating applied to the first major surface, the inorganic coating formed from a composition comprising a flame retardant blend that includes:
a phosphate compound;
a borate compound comprising boron trioxide;
a filler comprising three or more of calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, fumed silica, and aluminum oxide; and
a metal complexing agent;
wherein the flame retardant blend is present in an amount ranging from about 40 wt. % to about 80 wt. % based on the total weight of the inorganic coating; and wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.

9 . The flame-retardant building panel according to claim 8 wherein the cellulosic layer is wood.

10 . The flame-retardant building panel according to claim 8 wherein the inorganic coating is glass-forming.

11 . The flame-retardant building panel according to claim 8 wherein the inorganic coating has a solids content of at least 99% based on the total weight of the inorganic coating.

12 . The flame-retardant building panel according to claim 8 wherein the metal complexing agent comprises metal ion selected from the group consisting of iron, aluminum, zirconium, zinc, manganese, titanium, chromium, cobalt, and combinations thereof.

13 . A flame-retardant building panel comprising:
a body having a first major surface opposite a second major surface, the body comprising
a veneer layer having an upper surface opposite a lower surface;
an adhesive layer having an upper surface opposite a lower surface; and
a substrate layer having an upper surface opposite a lower surface;
an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes:
a phosphate compound;
a borate compound comprising boron trioxide; and
a metal complexing agent comprising iron;
wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1; wherein the first major surface of the body comprises the upper surface of the veneer layer; and wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.

14 . The flame-retardant building panel according to claim 13 , wherein the veneer layer has a thickness ranging from about 10 mils to about 100 mils, as measured between the upper surface and the lower surface of the veneer layer.

15 . The flame-retardant building panel according to claim 13 , wherein the adhesive layer has a thickness ranging from about 5 mils to about 15 mils, as measured between the upper surface and the lower surface of the adhesive layer.

16 . The flame-retardant building panel according to claim 13 , wherein the substrate layer has a thickness ranging from about 20 mils to about 100 mils, as measured between the upper surface and the lower surface of the veneer layer.

17 . The flame-retardant building panel according to claim 13 , wherein the veneer layer comprises a cellulosic material.

18 . The flame-retardant building panel according to claim 13 , wherein the adhesive layer comprises a thermoplastic polymer.

19 . The flame-retardant building panel according to claim 13 wherein the inorganic coating has a thickness ranging from about 0.5 mils to about 5.0 mils.

20 . The flame-retardant building panel according to claim 13 wherein the inorganic coating is substantially clear.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Hughes John E
• Huntzinger Suzanne M

Classifications

• E04B2103/06

  of metal · CPC title

• B32B2311/30

  Iron, e.g. steel · CPC title

• B32B2307/7265

  Non-permeable · CPC title

• B32B2307/412

  Transparent · CPC title

• B32B2307/3065

  Flame resistant or retardant, fire resistant or retardant · CPC title