# US 11,898,049 B2 · High solids coatings for building panels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,898,049 B2 - Document ID: US11898049B2 - Status: Granted - Kind: B2 - Application number: 17/529,540 - Filed: 2021-11-18 - Published: 2022-03-10 - Granted: 2024-02-13 - Earliest claimed: 2017-08-29 - Assignees: AWI Licensing LLC - Applicants: Armstrong World Industries, Inc. - Inventors: John E. Hughes; Steven L Masia - Web page: https://patentgrep.com/patent/US11898049B2 ## CPC - C09D 131/04: Homopolymers or copolymers of vinyl acetate - C08K 3/22: of metals - C08K 3/26: Carbonates; Bicarbonates - C09D 7/20: Diluents or solvents - C09D 7/43: Thickening agents - C09D 7/45: Anti-settling agents - C09D 7/61: inorganic - C09D 7/63: organic - E04C 2/043: {of plaster (E04C2/049 takes precedence)} - C08K 3/34: Silicon-containing compounds - C08K 5/10: Esters; Ether-esters - C08K 2003/2227: {of aluminium} - C08K 2003/2241: {Titanium dioxide} - C08K 2003/265: {Calcium, strontium or barium carbonate} - C08L 2205/03: containing three or more polymers in a blend - E04C 2002/005: {Appearance of panels} - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) ## Abstract Described herein is a coating composition suitable for application to a building panel. The coating composition comprises inorganic pigment, liquid carrier, and a humectant comprising a first ester-containing compound. The liquid carrier may be present in an amount ranging from about 10 wt. % to about 30 wt. % based on the total weight of the coating composition. Described herein are also building panels coated with the coating composition and methods of their production. ## Claims ### Claim 1 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-filling 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 the binder are present in a weight ratio of at least about 5:1; wherein the viscosity modifier comprises a humectant and a dispersant; and wherein the humectant and the dispersant are present in a weight ratio ranging from about 1:1 to about 4:1; and wherein the pigment comprises titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth. ### Claim 2 (depends on 1) The building system according to claim 1, wherein the Tg of the binder is at least 30° C. ### Claim 3 (depends on 1) The building system according to claim 1, wherein the binder is a styrene acrylic copolymer. ### Claim 4 (depends on 3) The building system according to claim 3, wherein the styrene acrylic copolymer has a pH ranging from about 7.5 to about 9. ### Claim 5 (depends on 1) The building system according to claim 1, wherein the binder is polyvinyl acetate. ### Claim 6 (depends on 5) The building system according to claim 5, wherein the polyvinyl acetate has a pH of about 7.0. ### Claim 7 (depends on 1) The building system according to claim 1, wherein the humectant is selected from the group consisting of ester-containing humectants including sugar-based esters and glycol-based esters. ### Claim 8 (depends on 1) The building system according to claim 1, wherein the dispersant comprises an ionic dispersant. ### Claim 9 (depends on 1) The building system according to claim 1, wherein the dispersant comprises a non-ionic dispersant. ### Claim 10 (depends on 1) The building system according to claim 1, wherein the pigment and the binder are present in a weight ratio of at least 7:1. ### Claim 11 (depends on 1) The building system according to claim 1, wherein the coating is applied in an amount ranging from about 10 g/ft2 to about 70 g/ft2. ### Claim 12 (depends on 1) The building system according to claim 1, wherein the seam-filling material comprises gypsum plaster. ### Claim 13 (depends on 1) The building system according to claim 1, 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, and the seam is located between adjacent 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. ### Claim 14 (depends on 13) The building system according to claim 13, 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. ### Claim 15 (depends on 14) The building system according to claim 14, wherein the coating exhibits a maximum airflow resistance of about 1,000 MKS Rayls. ### Claim 16 (depends on 1) The building system according to claim 1, wherein the humectant comprises at least one ester bond. ### Claim 17 A building system comprising: a first building panel and a second building panel, the first building panel positioned adjacent to the second building panel to form a seam 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-filling material, the coating comprising: a binder; a pigment blend comprising titanium dioxide, calcium carbonate, and diatomaceous earth; and a viscosity modifier; wherein the viscosity modifier comprises a humectant and a dispersant; and wherein the humectant and the dispersant are present in a weight ratio ranging from about 1:1 to about 4:1; and wherein the humectant comprises at least one ester bond. ### Claim 18 (depends on 17) The building system of claim 17, wherein the coating is applied to a central region of each the first and second building panels, and wherein a surface of the central region of the first building panel is parallel with a surface of the central region of the second building panel. ### Claim 19 (depends on 17) The building system of claim 17, wherein the binder has a pH of at least about 7.0 and a Tg of at least 20° C. ### Claim 20 A building system comprising: a plurality of building panels having at least a first building panel and a second building panel; a coating over the first building panel and the second building panel; and a seam-filling material between the first building panel and the second building panel; the coating comprising: a binder; a pigment blend comprising titanium dioxide, calcium carbonate, and diatomaceous earth; and a viscosity modifier; wherein the viscosity modifier comprises a humectant and a dispersant; wherein the humectant and the dispersant are present in a weight ratio ranging from about 1:1 to about 4:1; wherein the pigment and the binder are present in a weight ratio of at least about 7:1; and wherein the binder comprises styrene acrylic copolymer or polyvinyl acetate.