Thin layer UV curing coating on non-woven facers
A UV-cured coated facer includes a non-woven mat having a first side and a second side and an intermediate coating disposed on the first side of the non-woven mat. The intermediate coating includes a coating binder and a filler. The UV-cured coated facer also includes a UV-curable coating composition disposed on the intermediate coating, wherein the UV-curable coating composition is essentially free of a filler.
1 . A UV-cured coated facer comprising:
a non-woven mat having a first side and a second side;
50 g/m 2 to 300 g/m 2 of a cured intermediate coating disposed on the first side of the non-woven mat; wherein the cured intermediate coating comprises 5.5 to 20 weight percent of a coating binder and at least 75 weight percent of a filler, wherein the coating binder comprises a water-based polymer emulsion or solution; and
a UV-cured coating composition disposed on the cured intermediate coating, wherein said UV-cured coating composition is essentially free of a filler, wherein the UV-cured coating composition comprises the reaction product of at least one polyfunctional oligomer, at least one reactive diluent, and at least one photoinitiator blend comprising a Type II photoinitiator and an amine, and is applied to the intermediate layer with a thickness of 5 μm to 100 μm;
wherein the UV-cured coated facer has a Gurley air permeation number from 50,000 s to 150,000 s.
2 . The UV-cured coated facer of claim 1 , where the UV-cured coated facer has a percent weight loss that is 50% less than a facer with a comparable filled coating when an abrasion test is performed by cycling a wire bristle brush head on the facer for 50 cycles.
3 . The UV-cured coated facer of claim 1 , wherein the UV-cured coating composition has a solids content with a weight percent greater than 90%.
4 . The UV-cured coated facer of claim 1 , where the reactive diluent is selected from (meth) acrylates, (meth) acrylic acids, vinyl aromatics, divinyl ethers, and N-vinyl pyrrolidone, and combinations thereof.
5 . The UV-cured coated facer of claim 1 , where the polyfunctional oligomer is selected from epoxy acrylates, urethane acrylates, polyester acrylates, polyether acrylates, soy oil acrylates and straight-chained acrylic oligomers.
6 . The UV-cured coated facer of claim 1 , where the UV-cured coating composition further comprises one or more additives selected from the group consisting of surfactants, UV stabilizers, oxygen inhibitors, and pigments.
7 . A construction board that includes the UV-cured coated facer of claim 1 .
8 . The construction board of claim 7 , wherein the second side of the coated facer is attached to a gypsum board.
9 . The construction board of claim 7 , wherein the second side of the coated facer is attached to a polyisocyanurate board.
10 . A method for preparing a UV-cured coated facer comprising:
providing a non-woven fiber mat;
forming an intermediate coating on the non-woven fiber mat by coating the non-woven fiber mat with 50 g/m 2 to 300 g/m 2 of a coating composition including 5.5 to 20 weight percent of a coating binder and at least 75 weight percent of a filler;
curing the intermediate coating composition on the non-woven fiber mat;
coating the intermediate coating with UV-curable coating composition, wherein the UV-curable coating composition comprises at least one polyfunctional oligomer, at least one reactive diluent, and at least one photoinitiator blend comprising a Type II photoinitiator and an amine, and is essentially free of a filler, wherein the UV-curable coating composition is applied to the intermediate layer at a thickness of 5 μm to 100 μm; and
supplying a UV-light source to cure the UV-curable coating composition, forming a UV-cured coated facer;
wherein the UV-cured coated facer has a Gurley air permeation number from 50,000 s to 150,000 s.
11 . The method of claim 10 , where the UV-curable coating composition has a solids content with a weight percent of at least 90%.
12 . The method of claim 11 , where wherein said UV-curable coating composition has a solids content with a weight percent of at least 99%.
13 . The method of claim 10 , where the reactive diluent is selected from (meth) acrylates, (meth) acrylic acids, vinyl aromatics, divinyl ethers, and N-vinyl pyrrolidone, and combinations thereof.
14 . The method of claim 10 , where the polyfunctional oligomer is selected from epoxy acrylates, urethane acrylates, polyester acrylates, polyether acrylates, soy oil acrylates and straight-chained acrylic oligomers.
15 . The method of claim 10 , where the UV curable coating composition further comprises an additive selected from the group consisting of surfactants, UV stabilizers, oxygen inhibitors, and pigments.
16 . The method of claim 10 , where the non-woven fiber mat is a non-woven glass fiber mat.