Flame retardant clear coatings for building panels

Patent metadata

Field	Value
Publication number	US-2018347186-A1
Application number	US-201815994242-A
Country	US
Kind code	A1
Filing date	May 31, 2018
Priority date	May 31, 2017
Publication date	Dec 6, 2018
Grant date	—

Abstract

Described herein is 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 being optically transparent and flame retardant and comprising a silicate compound; and wherein the inorganic flame retardant coating is substantially transparent such that the first major surface of the body is visible through the inorganic coating.

First claim

1 . 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 being optically transparent and flame retardant and comprising a silicate compound; and wherein the inorganic flame retardant coating is substantially transparent such that the first major surface of the body is visible through the inorganic coating.

2 . The flame-retardant building panel according to claim 1 , wherein the first major surface of the body is wood.

3 . The flame-retardant building panel according to claim 1 , wherein the inorganic coating further comprises a dispersant present in an amount ranging from a non-zero value up to about 1.5 wt. % based on the total weight of the inorganic coating.

4 .- 5 . (canceled)

6 . The flame-retardant building panel according to claim 1 , wherein the inorganic coating comprises up to about 2 wt. % of organic components based on the total weight of the inorganic coating, wherein the organic component is selected from the groups consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

7 . (canceled)

8 . The flame-retardant building panel according to claim 1 , wherein the inorganic coating is present in an amount ranging from about 40 g/m 2 to about 120 g/m 2 .

9 . The flame-retardant building panel according to claim 1 , wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

10 . The flame-retardant building panel according to claim 1 , wherein the inorganic compound further comprises alumina trihydrate present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % based on the total weight of the inorganic coating.

11 . (canceled)

12 . The flame-retardant building panel according to claim 1 , wherein the inorganic compound further comprises an oxidizer.

13 .- 14 . (canceled)

15 . The flame-retardant building panel according to claim 1 , wherein the composition is formed from a composition having a pH ranging from about 9 to less than about 13.

16 . 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 formed from a coating composition comprising a silicate compound; and wherein the coating composition has a minimum pH of 9.

17 .- 19 . (canceled)

20 . The flame-retardant building panel according to claim 16 , wherein the inorganic coating has a solids content of at least 99 wt. % based on the total weight of the inorganic coating.

21 . The flame-retardant building panel according to claim 16 , wherein the inorganic coating comprises up to about 2 wt. % of organic components based on the total weight of the inorganic coating wherein the organic component is selected from the group consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

22 .- 23 . (canceled)

24 . The flame-retardant building panel according to claim 16 , wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

25 .- 26 . (canceled)

27 . The flame-retardant building panel according to claim 16 , wherein the inorganic compound further comprises an oxidizer.

28 . (canceled)

29 . The flame-retardant building panel according to claim 16 , wherein the inorganic coating further comprises filler selected from the group consisting of calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, silica, fumed silica, and combinations thereof.

30 . The flame-retardant building panel according to claim 16 , wherein the composition is formed from a composition having a pH ranging from about 10 to less than about 13.

31 . The flame-retardant building panel according to claim 16 , wherein the inorganic flame retardant coating is substantially transparent such that the first major surface of the body is visible through the inorganic coating.

32 .- 41 . (canceled)

42 . A flame-retardant building panel comprising:
a body having a first major surface opposite a second major surface; a top coat comprising:
a first sub-layer atop the first major surface of the body, the first sub-layer comprising a first silicate compound; and
a second sub-layer atop the first sub-layer, the second sub-layer comprising a second silicate compound and a wax; and
wherein top coat is optically transparent such that the first major surface of the body is visible through the top coat.

43 . (canceled)

44 . The flame-retardant building panel according to claim 42 , wherein the first sub-layer is formed from a first composition comprising the first silicate compound and has a minimum pH of about 9, and wherein the second sub-layer is formed from a second composition comprising the second silicate compound and the organic wax and has a minimum pH of about 9.

45 .- 52 . (canceled)

53 . The flame-retardant building panel according to claim 42 , wherein the top coat further comprises a third sub-layer that is atop the second sub-layer, the third sub-layer comprising an organic component in an amount of at least 40 wt. % based on the total dry-weight of the third sub-layer.

54 .- 66 . (canceled)

Assignees

• Armstrong World Ind Inc

Inventors

• Hughes John E
• Zhang Linzhu
• Wang Michelle X

Classifications

• E04B1/942 Primary

  slab-shaped · CPC title

• C09D7/63

  organic · CPC title

• E04B9/366

  the principal plane of the slats being vertical · CPC title

• E04C2/10

  of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products ({E04C2/049}, E04C2/26 take precedence; {hydraulic cement and mineral fibres E04C2/04}) · CPC title

• E04B9/16

  the members lying in different planes · CPC title