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1. (WO2019046226) HIGH SOLIDS COATINGS FOR BUILDING PANELS
Anmerkung: Text basiert auf automatischer optischer Zeichenerkennung (OCR). Verwenden Sie bitte aus rechtlichen Gründen die PDF-Version.

WHAT IS CLAIMED IS:

1. A coated building panel comprising:

a body comprising a first major surface and a side surface that intersects the first major surface;

a coating applied to at least one of the first major surface or the side surface, the coating comprising:

a binder having a pH of at least about 7.0 and a Tg of at least 20°C;

a pigment; and

a viscosity modifier;

wherein the pigment and binder are present in a weight ratio of at least about 5: 1.

2. The coated building panel according to claim 1, wherein the Tg of the binder is at least 30 °C

3. The coated building panel according to any one of claims 1 to 2, wherein the binder is a styrene acrylic copolymer.

4. The coated building panel according to claim 3, wherein the styrene acrylic copolymer has a pH ranging from about 7.5 to about 9.

5. The coated building panel according to any one of claims 1 to 2, wherein the binder is polyvinyl acetate.

6. The coated building panel according to claim 5, wherein the polyvinyl acetate has a pH of about 7.0.

7. The coated building panel according to any one of claims 1 to 6, wherein the viscosity modifier comprises a humectant and a dispersant.

8. The coated building panel according to claim 7, wherein humectant and the dispersant are present in a weight ratio ranging from about 1: 1 to about 4: 1.

9. The coated building panel according to any one of claims 7 to 8, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.

10. The coated building panel according to any one of claims 7 to 9, wherein the dispersant comprises an ionic dispersant.

11. The coated building panel according to any one of claims 7 to 10, wherein the dispersant comprises a non-ionic dispersant.

12. The coated building panel according to any one of claims 1 to 11, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

13. The coated building panel according to any one of claims 1 to 12, wherein the pigment and binder are present in a weight ratio of at least 7: 1.

14. The coated building panel according to any one of claims 1 to 13, wherein the body comprises gypsum board.

16. The coated building panel according to claim 1, wherein the coating is applied in an amount ranging from about 10 g/ft 2 to about 70 g/ft 2.

17. The coated building panel according to claim 1, wherein the coating exhibits an MKS Rayls value of at most 1,000.

18. A coating composition comprising:

a liquid carrier;

a solid blend comprising:

a binder having a pH of at least about 7.0 and a Tg of at least 20°C;

a pigment; and

a viscosity modifier;

wherein the pigment and binder are present in a weight ratio of at least about 5: 1, and wherein the liquid carrier is present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the coating composition.

19. The coating composition according to claim 18, wherein the Tg of the binder is at least 30 °C

20. The coating composition according to any one of claims 18 to 19, wherein the binder is a styrene acrylic copolymer.

21. The coating composition according to claim 20, wherein the styrene acrylic copolymer has a pH ranging from about 7.5 to about 9.

22. The coating composition according to any one of claims 18 to 19, wherein the binder is polyvinyl acetate.

23. The coating composition according to claim 22, wherein the polyvinyl acetate has a pH of about 7.0.

24. The coating composition according to any one of claims 18 to 23, wherein the viscosity modifier comprises a humectant and a dispersant.

25. The coating composition according to claim 24 wherein humectant and the dispersant are present in a weight ratio ranging from about 1: 1 to about 4: 1.

26. The coating composition according to any one of claims 24 to 25, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.

27. The coating composition according to any one of claims 24 to 26, wherein the dispersant comprises an ionic dispersant.

28. The coating composition according to any one of claims 24 to 27, wherein the dispersant comprises a non-ionic dispersant.

29. The coating composition according to any one of claims 18 to 28, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

30. The coating composition according to any one of claims 18 to 29, wherein the pigment and binder are present in a weight ratio of at least 7: 1.

31. The coating composition according to any one of claims 18 to 30, wherein the carrier comprises water.

32. The coating composition according to claim 31, wherein the carrier is present in an amount ranging from about 10 wt. % to about 25 wt. %.

33. A coated building panel comprising:

a body comprising a first major surface and a side surface that intersects the first major surface;

a coating applied to at least one of the first major surface or the side surface, the coating comprising:

a binder;

a pigment; and

a viscosity modifier comprising a humectant and a dispersant present in a weight ratio ranging from about 1: 1 to about 4: 1;

wherein the pigment and binder are present in a weight ratio of at least about 5: 1.

34. The coated building panel according to claim 33, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.

35. The coated building panel according to any one of claims 33 to 34, wherein the dispersant comprises an ionic dispersant.

36. The coated building panel according to any one of claims 33 to 35, wherein the dispersant comprises a non-ionic dispersant.

37. The coated building panel according to any one of claims 33 to 36, wherein the humectant and dispersant are present in a weight ratio ranging from about 1: 1 to about 2.5: 1

38. The coated building panel according to any one of claims 33 to 37, wherein the dispersant comprises an ionic dispersant.

39. The coated building panel according to any one of claims 33 to 38, wherein the dispersant comprises a non-ionic dispersant.

40. The coated building panel according to any one of claims 33 to 39, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

41. The coated building panel according to any one of claims 33 to 40, wherein the pigment and binder are present in a weight ratio of at least 7: 1.

42. The coated building panel according to any one of claims 33 to 41, wherein the coating is applied in an amount ranging from about 10 g/ft 2 to about 70 g/ft 2.

43. The coated building panel according to any one of claims 33 to 42, wherein the coating exhibits an MKS Rayls value of at most 1,000.

44. A coating composition comprising:

a liquid carrier;

a solid blend comprising:

a binder;

a pigment; and

a viscosity modifier comprising a humectant and a dispersant present in a weight ratio ranging from about 1: 1 to about 4: 1;

wherein the pigment and binder are present in a weight ratio of at least about 5: 1, and wherein the liquid carrier is present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the coating composition.

45. The coating composition according to claim 44, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.

46. The coating composition according to any one of claims 44 to 45, wherein the dispersant comprises an ionic dispersant.

47. The coating composition according to any one of claims 44 to 46, wherein the dispersant comprises a non-ionic dispersant.

48. The coating composition according to any one of claims 44 to 47, wherein the humectant and dispersant are present in a weight ratio ranging from about 1: 1 to about 2.5: 1

49. The coating composition according to any one of claims 44 to 48, wherein the dispersant comprises an ionic dispersant.

50. The coating composition according to any one of claims 44 to 49, wherein the dispersant comprises a non-ionic dispersant.

51. The coating composition according to any one of claims 44 to 50, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

52. The coating composition according to any one of claims 44 to 51, wherein the pigment and binder are present in a weight ratio of at least 7: 1.

53. The coating composition according to any one of claims 44 to 52, wherein the coating is applied in an amount ranging from about 10 g/ft 2 to about 70 g/ft 2.

54. The coating composition according to any one of claims 44 to 53, wherein the coating exhibits an MKS Rayls value of at most 1,000.

55. The coating composition according to any one of claims 44 to 54, wherein the carrier comprises water.

56. The coating composition according to claim 55, wherein the carrier is present in an amount ranging from about 10 wt. % to about 25 wt. %.

57. A method of creating an acoustical coating comprising:

a) spray-coating a composition to a building surface, the coating composition comprising a liquid carrier and a solid blend comprising pigment and binder, whereby the pigment and binder are present in a weight ratio of at least 5: 1.

58. The method according to claim 57, wherein the weight ratio of the pigment to binder is at least 7: 1.

59. The method according to any one of claims 57 to 58, wherein the binder has a pH of at least about 7.0 and a Tg of at least 20°C.

60. The method according to any one of claims 57 to 59, wherein the composition further comprises a humectant and a dispersant.

61. The method according to claim 60, wherein the humectant and the dispersant are present in a weight ratio ranging from about 4: 1 to about 1: 1

62. The method according to any one of claims 57 to 61, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

63. The method according to any one of claims 57 to 62, wherein the composition applied by spray-coating in an amount ranging from about 10 g/ft 2 to about 70 g/ft 2.

64. The method according to any one of claims 57 to 63, wherein during or after step a), the composition is dried, thereby driving off the liquid carrier.

65. The method according to claim 64, wherein subsequent to step a), the building surface is concealed by the pigment and binder of the composition.

66. The method according to any one of claims 57 to 61, wherein the building surface is one or more gypsum boards.

67. A building system comprising

a first building panel positioned adjacent to a second building panel, and a seam formed between the first and second building panels;

a seam-filling material applied to the seam;

a coating applied to the first and second building panels and the seam-filing material, the coating comprising:

a binder having a pH of at least about 7.0 and a Tg of at least 20°C;

a pigment; and

a viscosity modifier;

wherein the pigment and binder are present in a weight ratio of at least about 5: 1.

68. The building system according to claim 67, wherein the Tg of the binder is at least 30 °C

69. The building system according to any one of claims 67 to 68, wherein the binder is a styrene acrylic copolymer.

70. The building system according to claim 67, wherein the styrene acrylic copolymer has a pH ranging from about 7.5 to about 9.

71. The building system according to any one of claims 67 to 69, wherein the binder is polyvinyl acetate.

72. The building system according to claim 71, wherein the polyvinyl acetate has a pH of about 7.0.

73. The building system according to any one of claims 67 to 72, wherein the viscosity modifier comprises a humectant and a dispersant.

74. The building system according to claim 73, wherein humectant and the dispersant are present in a weight ratio ranging from about 1 : 1 to about 4: 1.

75. The building system according to any one of claims 73 to 74, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters.

76. The building system according to any one of claims 73 to 75, wherein the dispersant comprises an ionic dispersant.

77. The building system according to any one of claims 73 to 76, wherein the dispersant comprises a non-ionic dispersant.

78. The building system according to any one of claims 67 to 77, wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.

79. The building system according to any one of claims 67 to 78, wherein the pigment and binder are present in a weight ratio of at least 7: 1.

80. The building system according to any one of claims 67 to 79, wherein the body comprises gypsum board.

81. The building system according to claims 67 to 80, wherein the coating is applied in an amount ranging from about 10 g/ft 2 to about 70 g/ft 2.

82. The building system according to claims 67 to 81, wherein the seam- filing material comprises gypsum plaster.

83. The building system according to claims 67 to 82, wherein the seam- filing material comprises gypsum plaster.

84. The building system according to claims 67 to 83, wherein the first building panel and the second building panel are formed from gypsum board.

85. The building system according to claims 67 to 81,

wherein each of the first and second building panels comprise a first major surface opposite a second major surface and a side surface extending between the first and second major surfaces of the first building panel, and the seam is located between adjacent most side surfaces of the first and second building panel, and

wherein the seam-filling material is applied to a portion of the first major surface of the first building panel and a portion of the first major surface of the second building panel; and wherein the coating is applied continuously across the first major surface of the first building panel, the seam-filling material, and the first major surface of the second building panel.

86. The building system according to claim 85, wherein the first major surface of the first building panel has a first aesthetic appearance and the seam-filling material has a second aesthetic appearance, the first aesthetic appearance being different from the second aesthetic appearance, and wherein the coating substantially masks both the first and second aesthetic appearance.

87. The building system according to claim 86, wherein the coating exhibits a maximum airflow resistance of about 1,000 MKS Rayls.