US-20260125572-A1 - COATING COMPOSITIONS, COATED BUILDING PANELS, AND METHODS FOR MAKING THE SAME

Abstract

A coating composition includes a crosslinking binder composition comprising crosslinking functional groups or crosslinker, a pigment composition, a flame retardant, a filler composition, and a biocide. A building panel includes a substrate having a first major surface opposite a second major surface and a side surface extending there-between, and a coating composition over at least one of the first major surface, the second major surface, and the side surface, the coating composition including a crosslinkable binder composition including a crosslinker and a binding agent, a pigment composition, a flame retardant, and a filler composition.

Inventors

• Ying Chang
• Timothy ASTON
• Brian BAKEY
• Diane Artman
• Michael PELFREY
• Anthony PETRICCA

Assignees

• ARMSTRONG WORLD INDUSTRIES, INC.

Dates

Publication Date

20260507

Application Date

20251030

Claims (20)

1. 1 . A coating composition comprising: a crosslinkable binder composition comprising a binding agent; a pigment composition; a flame retardant filler; a filler composition; and a biocide.
2. 2 . The coating composition according to claim 1 , wherein the binder composition comprises an acrylic copolymer.
3. 3 . The coating composition according to claim 1 , wherein the binder composition comprises vinyl-acrylic latex.
4. 4 . The coating composition according to claim 1 , wherein the binder composition comprises a pH ranging from about 5.5 to about 6.5.
5. 5 . The coating composition according to claim 1 , wherein the binder composition has a glass transition temperature below 1° C.
6. 6 . The coating composition according to claim 1 , wherein the binder composition comprises a blend of a first binder and a second binder, wherein the first binder has a first glass transition temperature, and the second binder has a second glass transition temperature that is different than the first glass transition temperature.
7. 7 . The coating composition according to claim 1 comprising a filler to binder ratio ranging from about 0.1 to about 20.
8. 8 . The coating composition according to claim 1 comprising a filler to binder ratio ranging from about 1:1 to about 4:1.
9. 9 . The coating composition according to claim 1 , further comprising a humectant comprising a hydrophobic polymer emulsion.
10. 10 . A building panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending there-between; and a coating composition over at least one of the first major surface, the second major surface, and the side surface, the coating composition comprising: a crosslinkable binder comprising one or more hydroxy, carboxy, amine, glycidyl, N-methylol, isocyanate, carbodiimide or aziridine; a pigment composition; a flame retardant; and a filler composition.
11. 11 . The building panel according to claim 10 , wherein the coating composition is present in an amount ranging from about 30 g/sqft to 200 g/sqft.
12. 12 . The building panel according to claim 10 , wherein the binder composition comprises a pH ranging from about 5.5 to about 6.5.
13. 13 . The building panel according to claim 10 , wherein the binder composition comprises a glass transition temperature below 1° C.
14. 14 . The building panel according to claim 10 , further comprising a second coating composition over one of the first major surface and the second major surface, wherein the second coating composition comprises a binder composition that is different than the coating composition over the side surface.
15. 15 . A surface covering system comprising: a plurality of building panels configured to be positioned adjacent each other, each building panel of the plurality of building panels comprising: a substrate having a first major surface opposite a second major surface and a side surface extending there-between; and a coating composition over at least one of the first major surface, the second major surface, and the side surface, the coating composition comprising: a crosslinkable binder comprising one or more hydroxy, carboxy, amine, glycidyl, N-methylol, isocyanate, carbodiimide or aziridine; a pigment composition; a flame retardant; and a filler composition.
16. 16 . The surface covering system according to claim 15 , wherein the coating composition is present in an amount ranging from about 30 g/sqft to 200 g/sqft.
17. 17 . The surface covering system according to claim 15 , wherein the coating composition further comprises a biocide.
18. 18 . The surface covering system according to claim 15 , wherein the binder composition comprises vinyl-acrylic latex.
19. 19 . The surface covering system according to claim 15 , wherein the binder composition comprises a pH ranging from about 5.5 to about 6.5.
20. 20 . The surface covering system according to claim 15 , wherein the binder composition comprises a glass transition temperature below 1° C.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to U.S. Provisional Patent Application No. 63/715,587, filed on Nov. 3, 2024, the entirety of which is incorporated by reference herein. FIELD OF THE DISCLOSURE The present disclosure relates to coating compositions for coating panels, such as ceiling and wall panels, and more particularly to coating compositions for impact-resistance. BACKGROUND Building materials, such as planks and panels of ceiling and wall systems, are commonly coated with coating compositions, such as paints, for aesthetic purposes. These building materials are susceptible to damage on the surfaces during transport, thus creating wasted material and increasing costs. Accordingly, those skilled in the art continue research and development in the field of coating compositions to increase impact resistance and reduce defects. SUMMARY This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below. Applicants have discovered coating compositions useful for application on panels, such as wall or ceiling panels. A coating composition includes a crosslinkable binder composition including a crosslinker and a binding agent, a pigment composition, a flame retardant, a filler composition, and a biocide. In one example, the binder composition includes an acrylic copolymer. In one example, the binder composition includes vinyl-acrylic latex. In one example, the binder composition includes a pH ranging from about 4.5 to about 8.5. In one example, the binder composition has a glass transition temperature below ambient temperature. In one example, the binder composition has a glass transition temperature below 10° C. In one example, the binder composition includes a glass transition temperature below 1° C. In one example, the binder composition includes a viscosity less than 500 cps. In one example, the coating composition has a solids content ranging from about 60 wt. % to about 75 wt. %. In one example, the binder composition includes a blend of a first binder and a second binder. In one example, the first binder has a first glass transition temperature and the second binder has a second glass transition temperature that is different than the first glass transition temperature. In one example, the coating composition includes a filler to binder ratio ranging from about 0.1 to about 20. In one example, the coating composition includes a filler to binder ratio ranging from about 1:1 to about 4:1. In one example, the coating composition includes a filler to binder ratio of about 2:1. In one example, the pigment composition includes titanium dioxide. In one example, the coating composition includes a humectant. In one example, the humectant includes a hydrophobic polymer emulsion. In one example, the humectant includes a pH ranging from about 7 to about 9. In one example, the coating composition includes clay. In one example, the coating composition includes a calcined extender. In one example, the coating composition includes a dispersant. In one example, the coating composition includes a wetting agent. In one example, the coating composition includes a defoamer. In one example, the biocide includes one or more antimicrobial agents. A building panel includes a substrate having a first major surface opposite a second major surface and a side surface extending there-between, and a coating composition over the side surface, the coating composition including a crosslinkable binder composition including a crosslinker and a binding agent, a pigment composition, a flame retardant, and a filler composition. In one example, the coating composition is present in an amount ranging from about 30 g/sqft to about 200 g/sqft. In one example, the coating composition optionally includes a humectant. In one example, the coating composition further includes a biocide. In one example, the binder composition includes an acrylic copolymer. In one example, the binder composition includes vinyl-acrylic latex. In one example, the binder composition includes a pH ranging from about 4.5 to about 8.5. In one example, the binder composition has a glass transition temperature below ambient temperature. In one example, the binder composition has a glass transition temperature below 10° C. In one example, the binder composition includes a glass transition temperature below 1° C. In one example, the building panel includes a scrim over the first major surface. In one example, the scrim is a fiberglass scrim. In one e