Antimicrobial coating for building panel
In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.
1. A gypsum board comprising:
a gypsum core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide comprising at least one of an azole, a strobilurin, a fludioxonil, an isothiazolinone, a pyrithione, or a mixture thereof, at least one polymeric binder, and at least one pigment,
wherein the board exhibits at least a Level 3 finish, and
wherein the board satisfies at least one of the following:
the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.
2. The gypsum board of claim 1 , wherein the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 and a rating of at least 8 when tested in accordance to ASTM D3273-16.
3. The gypsum board of claim 1 , wherein the board exhibits a Level 5 finish.
4. The gypsum board of claim 1 , wherein the board exhibits an abrasion rating of at least 2 when tested in accordance to ASTM C1629/C1629M-15.
5. The gypsum board of claim 1 , wherein the at least one fungicide includes an azole, a strobilurin, a fludioxonil, or a mixture thereof.
6. The gypsum board of claim 1 , wherein the coating includes at least three fungicides.
7. The gypsum board of claim 6 , wherein the at least three fungicides include a mixture of thiabendazole, azoxystrobin, and fludioxonil.
8. The gypsum board of claim 1 , wherein the fungicides are present in the coating in an amount of from 1 ppm to 10,000 ppm.
9. The gypsum board of claim 1 , wherein the pigment comprises a white pigment.
10. The gypsum board of claim 9 , wherein the pigment comprises calcium carbonate, magnesium carbonate, or a mixture thereof.
11. The gypsum board of claim 10 , wherein the pigment further comprises a titanium dioxide.
12. The gypsum board of claim 1 , wherein the pigment has a brightness of at least 90% as determined in accordance to T534 om-76 and/or a median size of from 0.1 microns to 5 microns.
13. The gypsum board of claim 1 , wherein the polymeric binder comprises a vinyl acetate polymer or copolymer, an acrylic polymer or copolymer, a styrene polymer or copolymer, a vinyl acrylic polymer or copolymer, a cellulose, a starch, or a mixture thereof.
14. The gypsum board of claim 1 , wherein the polymeric binder comprises an acrylic polymer or copolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, a vinyl acrylic copolymer, or a mixture thereof.
15. The gypsum board of claim 1 , wherein the polymeric binder comprises a mixture of an acrylic polymer or copolymer, a styrene butadiene copolymer, and a cellulose.
16. The gypsum board of claim 1 , wherein the coating comprises a surfactant.
17. The gypsum board of claim 1 , wherein the coating comprises a wax.
18. The gypsum board of claim 17 , wherein the wax comprises a polyolefin wax.
19. The gypsum board of claim 1 , wherein the facing material comprises a paper.
20. The gypsum board of claim 1 , wherein the facing material comprises a glass mat.
21. A method of making the gypsum board of claim 1 , the method comprising:
providing a first facing material,
depositing a gypsum slurry onto the first facing material,
providing a second facing material onto the gypsum slurry, and
wherein at least one of the first facing material and the second facing material includes a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment.
22. The method of claim 21 , wherein the coating is applied to the first facing material prior to depositing the gypsum slurry.
23. The method of claim 21 , wherein the coating is applied to the second facing material prior to providing on top of the gypsum slurry.
24. A building panel comprising:
a cementitious core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide comprising an azole, a strobilurin, a fludioxonil, or a mixture thereof, at least one polymeric binder, and at least one pigment, and
wherein the panel satisfies at least one of the following:
the panel exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the panel exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.
25. A gypsum board comprising:
a gypsum core having a first side and a second side opposing the first side,
at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder comprising an acrylic polymer or copolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, a vinyl acrylic copolymer, or a mixture thereof, and at least one pigment,
wherein the board exhibits at least a Level 3 finish, and
wherein the board satisfies at least one of the following:
the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15, or
the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16.
26. The gypsum board of claim 25 , wherein the polymeric binder comprises a mixture of an acrylic polymer or copolymer and a styrene butadiene copolymer and further comprises a cellulose.