CLAY CONTAINING PROTECTIVE COATINGS
Described herein is a building panel comprising: a substrate; a first coating applied to the substrate, the first coating comprising a flame-retardant composition; a second coating applied to the first coating, the second coating comprising: laponite clay; and a polymeric composition comprising a cured alkyd resin; wherein the building panel comprises an exposed surface formed by the second coating, and wherein the second coating has a solids content of at least 99%.
1 . A building panel comprising:
a substrate;
a first coating applied to the substrate, the first coating comprising a flame-retardant composition;
a second coating applied to the first coating, the second coating comprising:
laponite clay; and
a polymeric composition comprising a cured alkyd resin;
wherein the building panel comprises an exposed surface formed by the second coating, and wherein the second coating has a solids content of at least 99%.
2 . The building panel according to claim 1 , wherein the flame-retardant composition comprises a silicate.
3 . The building panel according to claim 1 , wherein the laponite clay is present in an amount ranging from about 0.1 wt. % to about 3 wt. % based on the total weight of the second coating.
4 . The building panel according to claim 1 , wherein the polymeric composition is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the second coating.
5 . The building panel according to claim 1 , wherein the polymeric composition and laponite clay are present in a weight ratio of at least 20:1.
6 . The building panel according to claim 1 , wherein the second coating further comprises a coupling agent, optionally wherein the coupling agent is a silane-functional.
7 . (canceled)
8 . The building panel according to claim 1 , wherein the cured alkyd resin is formed from an alkyd resin comprising short oil chain-stopped alkyd emulsion.
9 . (canceled)
10 . The building panel according to claim 1 , wherein the substrate comprises a cellulosic material.
11 . A coating composition comprising:
a liquid carrier;
an alkyd resin;
laponite clay;
wherein the alkyd resin and the laponite clay are present in a weight ratio of at least 20:1.
12 . The coating composition according to claim 11 , wherein the liquid carrier is present in an amount ranging from about 40 wt.% to about 70 wt. % based on the total weight of the coating composition.
13 . The coating composition according to claim 11 , wherein the alkyd resin is present in an amount ranging from about 30 wt.% to about 40 wt. % based on the total weight of the coating composition.
14 . The coating composition according to claim 11 , wherein the laponite clay is present in an amount ranging from about 0.01 wt. % to about 1.5 wt. % based on the total weight of the coating composition.
15 . The coating composition according to claim 11 , wherein the liquid carrier comprises water.
16 . The building panel according to claim 11 , wherein the coating composition further comprises a coupling agent, optionally wherein the coupling agent is a silane-functional.
17 . (canceled)
18 . The building panel according to claim 11 , wherein the cured alkyd resin is formed from an alkyd resin comprising at least one of a short-oil chain stopped alkyd emulsion and a medium-oil chain stopped alkyd emulsion.
19 . (canceled)
20 . (canceled)
21 . (canceled)
22 . (canceled)
22 . A method of forming a protective coating comprising:
a) applying a coating composition to a substrate, the coating composition comprising an alkyd resin, laponite clay, and liquid carrier, wherein the alkyd resin and laponite clay are present in a weight ratio of at least 20:1;
b) curing the alkyd resin and drying off the liquid carrier to form the protective coating atop the building panel, the protective coating having a solids content of at least 99 wt. %.
23 . The method according to claim 22 , wherein the coating composition is applied to the building panel in step a) in an amount ranging from about 3.0 g/ft 2 to about 15.0 g/ft 2 .
24 . The method according to claim 22 , wherein the protective coating after step b) is present atop the building panel in an amount ranging from about 1.5 g/ft 2 to about 8.0 g/ft 2 .
25 . The method according to claim 22 , wherein the liquid carrier comprises water.
26 . A method of forming a protective coating comprising:
a) applying a coating composition to a substrate having a flame-retardant coating applied thereto, wherein the coating composition is applied to the flame-retardant coating atop the substrate, the coating composition comprising an alkyd resin, laponite clay, and liquid carrier;
b) curing the alkyd resin and drying off the liquid carrier to form the protective coating atop the substrate, the protective coating having a solids content of at least 99 wt. %.
27 . The method according to claim 26 , wherein the coating composition is applied to the flame-retardant coating in step a) in an amount ranging from about 3.0 g/ft 2 to about 15.0 g/ft 2 .
28 . (canceled)
28 . A building panel comprising:
a substrate;
a coating applied to the substrate, the coating comprising:
laponite clay; and
a polymeric composition comprising a cured alkyd resin, the cured alkyd resin and the laponite clay present in a weight ratio of at least 20:1;
wherein the building panel comprises an exposed surface formed by the coating, and wherein the second coating has a solids content of at least 99%.
29 . The building panel according to claim 28 , wherein the laponite clay is present in an amount ranging from about 0.1 wt. % to about 3 wt. % based on the total weight of the coating.
30 . The building panel according to claim 28 , wherein the polymeric composition is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the coating.
31 . The building panel according to claim 28 , wherein the second coating further comprises a coupling agent, optionally wherein the coupling agent is a silane-functional.
32 . (canceled)
33 . The building panel according to claim 28 , wherein the cured alkyd resin is formed from an alkyd resin comprising at least one of a short-oil chain stopped alkyd emulsion and a medium-oil chain stopped alkyd emulsion.
34 . The building panel according to claim 28 , wherein the coating is present in an amount ranging from about 1.5 g/ft 2 to about 8.0 g/ft 2 .
35 . (canceled)