Flame retardant clear coatings for building panels
The present invention is directed to a flame-retardant building panel comprising a body having a first major surface opposite a second major surface, an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes a phosphate compound, and a metal complexing agent. In other aspect, the invention is a method of forming a flame-retardant building panel comprising: a) applying an inorganic coating composition to a major surface of a body; and b) drying the inorganic coating composition at an elevated temperature.
1 . A flame-retardant building panel comprising:
a body comprising a cellulosic layer, the body having a first major surface opposite a second major surface, and the first major surface of the body comprising the cellulosic layer;
an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes:
a phosphate compound;
a borate compound comprising boron trioxide;
a filler comprising calcium carbonate, aluminum carbonate, magnesium carbonate, and fumed silica;
a cross-linker comprising triethanolamine; and
a metal complexing agent;
wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1; and
wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.
2 . The flame-retardant building panel according to claim 1 wherein the cellulosic material is wood.
3 . The flame-retardant building panel according to claim 1 wherein the inorganic coating is glass-forming.
4 . The flame-retardant building panel according to claim 1 wherein the inorganic coating has a solids content of at least 99% based on the total weight of the inorganic coating.
5 . The flame-retardant building panel according to claim 1 wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 75:1 to about 150:1.
6 . The flame-retardant building panel according to claim 1 wherein the inorganic coating has a thickness ranging from about 0.5 mils to about 5.0 mils.
7 . The flame-retardant building panel according to claim 1 wherein the metal ion is iron and a weight ratio of the phosphate compound to the metal ion is at least about 20,000:1.
8 . A flame-retardant building panel comprising:
a body comprising a cellulosic layer, the body having a first major surface opposite a second major surface, and the first major surface of the body comprising the cellulosic layer;
an inorganic coating applied to the first major surface, the inorganic coating formed from a composition comprising a flame retardant blend that includes:
a phosphate compound;
a borate compound comprising boron trioxide;
a filler comprising three or more of calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, fumed silica, and aluminum oxide; and
a metal complexing agent;
wherein the flame retardant blend is present in an amount ranging from about 40 wt. % to about 80 wt. % based on the total weight of the inorganic coating; and
wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.
9 . The flame-retardant building panel according to claim 8 wherein the cellulosic layer is wood.
10 . The flame-retardant building panel according to claim 8 wherein the inorganic coating is glass-forming.
11 . The flame-retardant building panel according to claim 8 wherein the inorganic coating has a solids content of at least 99% based on the total weight of the inorganic coating.
12 . The flame-retardant building panel according to claim 8 wherein the metal complexing agent comprises metal ion selected from the group consisting of iron, aluminum, zirconium, zinc, manganese, titanium, chromium, cobalt, and combinations thereof.
13 . A flame-retardant building panel comprising:
a body having a first major surface opposite a second major surface, the body comprising
a veneer layer having an upper surface opposite a lower surface;
an adhesive layer having an upper surface opposite a lower surface; and
a substrate layer having an upper surface opposite a lower surface;
an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes:
a phosphate compound;
a borate compound comprising boron trioxide; and
a metal complexing agent comprising iron;
wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1;
wherein the first major surface of the body comprises the upper surface of the veneer layer; and
wherein the inorganic coating has a curing temperature ranging from about 225° F. to about 275° F.
14 . The flame-retardant building panel according to claim 13 , wherein the veneer layer has a thickness ranging from about 10 mils to about 100 mils, as measured between the upper surface and the lower surface of the veneer layer.
15 . The flame-retardant building panel according to claim 13 , wherein the adhesive layer has a thickness ranging from about 5 mils to about 15 mils, as measured between the upper surface and the lower surface of the adhesive layer.
16 . The flame-retardant building panel according to claim 13 , wherein the substrate layer has a thickness ranging from about 20 mils to about 100 mils, as measured between the upper surface and the lower surface of the veneer layer.
17 . The flame-retardant building panel according to claim 13 , wherein the veneer layer comprises a cellulosic material.
18 . The flame-retardant building panel according to claim 13 , wherein the adhesive layer comprises a thermoplastic polymer.
19 . The flame-retardant building panel according to claim 13 wherein the inorganic coating has a thickness ranging from about 0.5 mils to about 5.0 mils.
20 . The flame-retardant building panel according to claim 13 wherein the inorganic coating is substantially clear.