High solids coatings for building panels
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.
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 directly 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 comprising a humectant;
wherein the pigment and the binder are present in a weight ratio of at least about 8.8:1; and
wherein the humectant is an ester.
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 claim 1 , wherein the binder is a styrene acrylic copolymer having a pH ranging from about 7.5 to about 9.
4. The coated building panel according to claim 1 , wherein the binder is polyvinyl acetate having a pH of about 7.0.
5. The coated building panel according to claim 1 , wherein the viscosity modifier comprises the humectant and a dispersant present in a weight ratio ranging from about 1:1 to about 4:1.
6. The coated building panel according to claim 1 , wherein the pigment is selected from one or more of titanium dioxide, calcium carbonate, alumina trihydrate, and diatomaceous earth.
7. The coated building panel according to claim 1 , wherein the humectant is selected from the group consisting of sugar-based esters, glycol-based esters, and combinations thereof.
8. 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 directly 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 humectant comprises at least one ester bond, and the humectant is present in an amount ranging from about 0.25 wt. % to about 2.5 wt. % based on the total dry-weight of the coating
wherein the pigment and the binder are present in a weight ratio of at least about 8.8:1.
9. The coated building panel according to claim 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 claim 8 , wherein the dispersant comprises an ionic dispersant.
11. The coated building panel according to claim 8 , wherein the dispersant comprises a non-ionic dispersant.
12. The coated building panel according to claim 8 , wherein the humectant and the dispersant are present in a weight ratio ranging from about 1:1 to about 2.5:1.