Sag resistant, formaldehyde-free coated fibrous substrate
AssigneeAWI Licensing LLC
InventorsLida Lu, Kenneth G. Caldwell
Life of this patent
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Abstract
The present invention relates to an improved formaldehyde-free coated fibrous substrate. The coating includes a crosslinked binder system which forms three dimensional networks when heat cured. After the coating is applied to the back of fibrous substrate and cured, the coating is capable of hygroscopic expansion which imparts excellent anti-sag properties. The coating is compatible with other coating systems with neutral or mild alkaline pH. The improvement being the binding system is neutralized with a volatile base so that it evaporates quickly so as not to hinder the cross-linking reaction.
Claims19
A coating composition for application to a building panel, the coating composition comprising a blend of:
- a polymeric binder comprising polyacrylic acid;
- a filler;
- a crosslinker that is a polyol selected from the group consisting of glycerol, dextrose, sucrose, fructose, sorbitol, and combinations thereof;
- a neutralizing agent;
- and
- a liquid carrier;
- wherein the coating composition is formaldehyde-free and has a pH ranging from about 8.0 to about 8.9;
- and
- wherein the filler and the polymeric binder are present in a weight ratio ranging from about 2:1 to about 6:1.
An aqueous coating composition for application to a building panel, the coating composition comprising a blend of:
- a polymeric binder that is a polyacrylic acid;
- a crosslinker that is a polyol selected from the group consisting of glycerol, dextrose, sucrose, fructose, sorbitol, and combinations thereof;
- a neutralizing agent;
- a filler;
- wherein the aqueous coating composition has a pH of about 8.0;
- and
- wherein a weight ratio of the filler to the polymeric binder is from about 2:1 to about 6:1, and the aqueous coating composition has a metal ion concentration of less than 1000 ppm.
A coating composition for application to a building panel, the coating composition comprising a blend of:
- a polymeric binder that is polyacrylic acid and that is at least partially neutralized with a volatile base;
- a polyol crosslinker selected from the group consisting of diethanolamine, triethanolamine, glycerol, dextrose, sucrose, fructose, sorbitol, and combinations thereof;
- a nonionic surfactant comprising a secondary alcohol ethoxylate;
- a liquid carrier;
- a filler;
- and
- wherein the coating composition is free of mica;
- wherein the coating composition is formaldehyde-free and is free of any single or multi-valence metal ions selected from sodium, potassium, and calcium;
- wherein the coating composition has a pH ranging from about 8.0 to about 8.9;
- and
- wherein a weight ratio of the filler to the polymeric binder ranges from about 2:1 to about 6:1.
Dependencies are inferred from the claim text.