High solids color face and edge coatings for building panels
Described herein is a coated building panel having a body and a surface coating atop the body, the surface coating comprising inorganic pigment and a polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone; wherein the surface coating comprises a liquid carrier in an amount less than about 1 wt. % based on the total weight of the surface coating.
1 . A coated building panel comprising:
a body comprising an upper surface opposite a lower surface and a side surface extending between the upper surface and the lower surface;
a surface coating atop the upper surface, the surface coating comprising:
inorganic pigment;
a binder comprising carboxylated polyvinyl acetate homopolymer; and
an anionic polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone;
wherein anionic groups are located on the terminal ends of the pendant side-chains; and
wherein the surface coating comprises a liquid carrier in an amount less than about 1 wt. % based on the total weight of the surface coating.
2 . The coated building panel according to claim 1 , wherein the polymeric dispersant comprises a hydrophobic portion and a hydrophilic portion.
3 . The coated building panel according to claim 1 , wherein the polymeric dispersant has a molecular weight of at least 1,000 Mn.
4 . The coated building panel according to claim 1 , wherein the polymeric dispersant is present in an amount ranging from about 0.05 wt. % to about 2.0 wt. % based on the total weight of the surface coating.
5 . The coated building panel according to claim 1 , wherein the inorganic pigment has a particle size ranging from about 15 nm to about 1,000 μm.
6 . The coating building panel according to claim 5 , wherein the inorganic pigment has a maximum particle size of about 500 nm.
7 . The coated building panel according to claim 1 , wherein the surface coating is present in an amount ranging from about 10 g/m 2 to about 132 g/m 2 .
8 . The coated building panel according to claim 1 , wherein the inorganic pigment is present in an amount ranging from about 70 wt. % to about 95 wt. % based on the total weight of the surface coating.
9 . The coated building panel according to claim 1 , wherein the binder has a glass transition temperature greater than about 21° C.
10 . The coated building panel according to claim 1 , wherein the binder is present in an amount ranging from about 5 wt. % to about 20 wt. % based on the total weight of the surface coating.
11 . The coated building panel according to claim 1 , wherein the anionic polyacrylic polymer comprises a salt group formed from a neutralization of an acid group with a compound forming a cation.
12 . A coated building panel comprising:
a body comprising an upper surface opposite a lower surface and a side surface extending between the upper surface and the lower surface;
a surface coating atop the upper surface, the surface coating comprising:
about 70 wt. % to about 95 wt. % of a pigment blend based on the total weight of the surface coating, the pigment blend comprising two or more inorganic pigments having a particle size ranging from 15 nm to 500 nm;
a binder comprising carboxylated polyvinyl acetate homopolymer; and
an anionic polymeric dispersant comprising a polymer backbone and pendant side chains extending from the polymer backbone;
wherein anionic groups are located on the terminal ends of the pendant side-chains;
wherein the anionic polymeric dispersant comprises a hydrophobic portion and a hydrophilic portion;
wherein the pigment blend comprises calcium carbonate and calcined diatomaceous earth; and
wherein the surface coating comprises less than 1 wt. % of a liquid carrier based on the total weight of the surface coating.
13 . The coated building panel according to claim 12 , wherein the anionic polyacrylic dispersant comprises a salt group formed from a neutralization of an acid group with a compound forming a cation.
14 . The coated building panel according to claim 12 , further comprising a thickener.
15 . The coated building panel according to claim 14 , wherein the thickener comprises hydroxyethylcellulose.
16 . The coated building panel according to claim 12 , wherein the pigment blend comprises a first pigment, a second pigment that is different than the first pigment, and a third pigment that is different than the first pigment and the second pigment.
17 . The coated building panel according to claim 12 , wherein the pigment blend comprises kaolin.