Granted Patent B2

US 12,269,962 · App. 18/115,701 · Granted Apr 8, 2025

Inventors: John E. Hughes (Lincoln University, PA); Linzhu Zhang (Ephrata, PA); Lori Jo L. Shearer (Millersville, PA)

Assignee: AWI Licensing LLC

C09D157/00C09D1/00C09D7/20C09D7/61C09D7/63

Abstract

Claims (34)

1. A coating composition comprising:

calcium carbonate;

titanium dioxide;

opacity pigment composite comprising TiO 2 encapsulated within a precipitated calcium carbonate shell;

calcined diatomaceous earth;

calcium chloride;

aluminum hydroxide; and

vinyl acrylic polymer,

wherein the weight ratio of calcium carbonate and calcined diatomaceous earth to vinyl acrylic polymer is from about 3:1 to about 15:1, from about 4:1 to about 12:1, from about 5:1to about 10:1, or from about 5:1 to about 8.5:1, based on the dry weight of the composition.

2. The coating composition of claim 1 , wherein the calcium carbonate is present in an amount from about 20 wt. % to about 40 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

3. The coating composition of claim 1 , wherein the titanium dioxide not part of the opacity pigment composite is present in an amount from about 10 wt. % to about 40 wt. %, from about 15 wt. % to about 35 wt. %, or from about 20 wt. % to about 30wt. %, based on the dry weight of the composition.

4. The coating composition of claim 1 , wherein the opacity pigment composite is present in an amount from about 8 wt. % to about 30 wt. %, from about 10 wt. % to about 25 wt. %, or from about 15 wt. % to about 20 wt. %, based on the dry weight of the composition.

5. The coating composition claim 1 , wherein the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition.

6. The coating composition of claim 1 , wherein the calcium chloride is present in an amount from about 2.5 wt. % to about 20 wt. %, from about 5wt. % to about 15 wt. %, or from about 5 wt. % to about 10 wt. %, based on the dry weight of the composition.

7. The coating composition of claim 1 , wherein the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5wt. % to about 15 wt. %, or from about 5 wt. % to about 10 wt. %, based on the dry weight of the composition.

8. The coating composition of claim 1 , wherein the vinyl acrylic polymer is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 15 wt. %, or from about 3 wt. % to about 10 wt. %, based on the dry weight of the composition.

9. The coating composition of claim 1 , wherein the composition further comprises a hydrophobic polymer emulsion, and wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %. from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

10. The coating composition of claim 1 , wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer, wherein the wetting and dispersing additive is present in an amount from about 0.1wt. % to about 5 wt. %. from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition, and wherein the wetting and dispersing additive has an acid value of about 2 mg KOH/g.

11. The coating composition of claim 1 , wherein the composition further comprises an ethoxylated acetylenic gemini surfactant, optionally wherein the surfactant is non-ionic, and wherein the ethoxylated acetylenic gemini surfactant is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1wt. %, or from about 0.01 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

12. The coating composition of claim 1 , wherein the composition contains no clay.

13. The coating composition of claim 1 , wherein the composition further comprises clay, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition, and wherein the clay comprises hectorite clay.

14. The coating composition of claim 1 , wherein the weight ratio of calcium carbonate to vinyl acrylic polymer is from about 2:1 to about 15:1, from about 2:1 to about 12:1, from about 2:1 to about 10:1, or from about 3:1 to about 8:1, based on the dry weight of the composition.

15. The coating composition of claim 1 , wherein the weight ratio of calcined diatomaceous earth to vinyl acrylic polymer is from about 0.5:1 to about 10:1, from about 0.75:1 to about 10:1, from about 1:1 to about 7:1, or from about 0.5:1 to about 4:1, based on the dry weight of the composition.

16. The coating composition of claim 1 ,

wherein the weight ratio of titanium dioxide not part of the opacity pigment composite, opacity pigment, and calcium carbonate to calcium chloride is from about 30:1 to about 5:1, from about 28:1 to about 5.5:1, from about 20:1 to about 6:1, or from about 10:1 to about 6:1, based on the dry weight of the composition.

17. A panel comprising a first major surface opposite a second major surface and a side surface extending there-between, the panel coated on at least one surface with a coating composition comprising:

calcium carbonate;

titanium dioxide;

opacity pigment composite comprising TiO 2 encapsulated within a precipitated calcium carbonate shell;

calcined diatomaceous earth;

calcium chloride;

aluminum hydroxide; and

vinyl acrylic polymer,

wherein the weight ratio of calcium carbonate and calcined diatomaceous earth to vinyl acrylic polymer is from about 3:1 to about 15:1, from about 4:1 to about 12:1, from about 5:1to about 10:1, or from about 5:1 to about 8.5:1, based on the dry weight of the composition.

Assignments (3)

Continuity (2)

References Cited (15)

Cited By (1)

US 12,703,805