Method of forming VOC and odor reducing building panels
Described herein are methods of forming a VOC and odor-reducing building panel. The methods include providing a substrate; applying a wet-state coating to a major surface of the substrate, the wet-state coating comprising carrier comprising water; and drying the wet-state coating, thereby evaporating at least 95 wt. % of the carrier to form a dry-state coating.
1. A method of forming a VOC and odor-reducing building panel comprising:
providing a substrate;
applying a wet-state coating to a major surface of the substrate, the wet-state coating comprising:
ethylene urea;
silica gel;
rheology modifier; and
carrier comprising water; and
drying the wet-state coating, thereby evaporating at least 95 wt. % of the carrier to form a dry-state coating.
2. The method according to claim 1 , wherein the wet-state coating is applied to a major surface of the substrate in an amount ranging from about 100 g/m 2 to about 1000 g/m 2 .
3. The method according to claim 1 , wherein the dry-state coating is present on the substrate in an amount ranging from about 50 g/m 2 to about 400 g/m 2 .
4. The method according to claim 1 , wherein the rheology modifier is selected from silicate mineral, alkali-swellable compounds, and combinations thereof.
5. The method according to claim 4 , wherein the rheology modifier is present in an amount ranging from about 0.5 wt. % to about 55 wt. %, based on the total weight of the dry-state coating.
6. The method according to claim 1 , wherein the water is present in an amount ranging from about 25 wt. % to about 75 wt. %, based on the total weight of the wet-state coating.
7. The method according to claim 1 , wherein the wet-state coating has a viscosity ranging from about 200 cps to about 4,000 cps as measured on a Brookfield viscometer at RPM at room temperature.
8. The method according to claim 1 , wherein the wet-state coating composition further comprises porous CaCO 3 .
9. A method of forming a VOC and odor-reducing acoustic building panel comprising:
providing an acoustic building panel substrate;
applying a wet-state coating to a major surface of the substrate, the wet-state coating comprising:
silica gel;
surfactant;
rheology modifier; and
carrier comprising water; and
drying the wet-state coating, thereby evaporating at least 95 wt. % of the carrier to form a dry-state coating.
10. The method according to claim 9 , wherein the wet-state coating is applied to a major surface of the substrate in an amount ranging from about 100 g/m 2 to about 1000 g/m 2 .
11. The method according to claim 9 , wherein the dry-state coating is present on the substrate in an amount ranging from about 50 g/m 2 to about 400 g/m 2 .
12. The method according to claim 9 , wherein the rheology modifier is selected from silicate mineral, alkali-swellable compounds, and combinations thereof.
13. The method according to claim 12 , wherein the rheology modifier is present in an amount ranging from about 0.5 wt. % to about 55 wt. %, based on the total weight of the dry-state coating.
14. The method according to claim 9 , wherein the wet-state coating has a viscosity ranging from about 200 cps to about 4,000 cps as measured on a Brookfield viscometer at RPM at room temperature.
15. The method according to claim 9 , wherein the wet-state coating composition further comprises porous CaCO 3 .
16. The method according to claim 9 , wherein the surfactant is a surfactant blend comprising a non-ionic surfactant and an ionic surfactant.
17. A method of forming a VOC and odor-reducing building panel comprising:
providing a substrate;
applying a wet-state coating to a major surface of the substrate, the wet-state coating comprising:
silica gel;
kaolin; and
carrier comprising water; and
drying the wet-state coating, thereby evaporating at least 95 wt. % of the carrier to form a dry-state coating.
18. The method according to claim 17 , wherein the kaolin has an average particle size ranging from about 0.5 μm to about 30 μm.
19. The method according to claim 17 , wherein the kaolin has a size distribution that has about 0.3% of the particles retained on a 325 mesh screen and a density of about 2.6 g/cm 3 .
20. The method according to claim 17 , wherein the wet-state coating composition further comprises ethylene urea.