Flame retardant coatings for building panels

Abstract

Described herein is a flame-retardant building panel comprising a body having a first major surface opposite a second major surface, an inorganic coating comprising a silicate compound, an alkali siliconate compound; and magnesium aluminosilicate, wherein the coating is atop the first major surface of the body.

Description

Attorney Docket No. 22020-00-WO-01-ABP FLAME RETARDANT COATINGS FOR BUILDING PANELS CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63 / 545392 filed on October 24, 2023, the disclosure of which is incorporated herein by reference in its entirety. BACKGROUND

[0002] Building products for interior room environments balance interests with respect to cosmetic value, material cost, structural integrity, and fire safety. Previous attempts at imparting a protective coating involved applying a composition to the major surfaces of a building panel. However, such previous attempts resulted poor performance over long time periods. Thus, there is a need for building panels that exhibit superior performance properties over the course of the timespan when the building panel is to be used... BRIEF SUMMARY

[0003] 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 comprising: a silicate compound; an alkali siliconate compound; and magnesium aluminosilicate; and wherein the coating is atop the first major surface of the body.

[0004] Other embodiments of the present invention include a flame-retardant building panel comprising: a cellulosic body having a first major surface opposite a second major surface; an inorganic coating comprising: a silicate compound; an alkali siliconate compound; and wherein the inorganic coating is atop the first major surface of the cellulosic body.

[0005] According to other embodiments, the present invention includes a flame-retardant building panel comprising: a body having a first major surface opposite a second major surface; an inorganic coating having an upper surface opposite a lower surface, the inorganic coating comprising: a silicate compound; an alkali siliconate compound; and a top coat; and wherein the inorganic coating is atop the first major surface of the body and the top coat is atop the upper surface of the inorganic coating.

[0006] In other embodiments, the present invention includes a flame-retardant coating composition comprising: a liquid carrier; a solid component comprising: a silicate compound; anAttorney Docket No. 22020-00-WO-01-ABP alkali siliconate compound; and magnesium aluminosilicate; wherein the flame-retardant coating has a pH greater than 8.

[0007] The present invention further includes embodiments directed to a method of forming a flame-retardant building panel comprising a) applying an inorganic coating composition to a major surface of a body; b) drying the inorganic coating composition at an elevated temperature ranging from about 150 °F to about 220 °F to form a flame-retardant coating atop the body; wherein the inorganic coating composition comprises a liquid carrier, a silicate compound, and an alkali siliconate compound; and wherein the flame-retardant coating has a solids content of at least 99 wt. % based on the total weight of the flame-retardant coating.

[0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0010] FIG. 1 is top perspective view of the building panel according to the present invention;

[0011] FIG. 2 is a cross-sectional view of the building panel according to the present invention, the cross-sectional view being along the II line set forth in FIG. 1;

[0012] FIG. 3 is cross-sectional view of a building panel according to other embodiments of the present invention, the cross-sectional view being along the II line set forth in FIG. 1; and

[0013] FIG. 4 is a ceiling system comprising the building panel of the present invention. DETAILED DESCRIPTION

[0014] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0015] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.Attorney Docket No. 22020-00-WO-01-ABP

[0016] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material.

[0017] The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top,” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such.

[0018] Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non- limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

[0019] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. According to the present application, the term “about” means + / - 5% of the reference value. According to the present application, the term “substantially free” less than about 0.1 wt. % based on the total of the referenced value.

[0020] Referring to FIGS. 1 and 4, the present invention includes a ceiling system 1 as well as a building panel 10 that may be used in the ceiling system 1. The ceiling system 1 may comprise at least one or more of the building panels 10 installed in an interior space, whereby the interior space comprises a plenum space 3 and an active room environment 2. The plenum space 3 is defined by the space occupied between a structural barrier 4 between floors of a building and the lower majorAttorney Docket No. 22020-00-WO-01-ABP surface 12 of the building panel 10. The plenum space 3 provides space for mechanical lines within a building (e.g., HVAC, electrical lines, plumbing, telecommunications, etc.). The active space 2 is defined by the space occupied beneath the upper major surface 11 of the building panel 10 for one floor in the building. The active space 2 provides room for the building occupants during normal intended use of the building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.).

[0021] Each of the building panels 10 may be supported in the interior space by one or more supports 5. Each of the building panels 10 are installed such that the upper major surface 11 of the building panel 10 faces the active room environment 2 and the lower major surface 12 of the building panel 10 faces the plenum space 3. The building panels 10 of the present invention have a superior protective face coating as well as exhibits superior fire safety – particularly when a fire originates in the active room environment 2 – without sacrificing the desired aesthetic appearance of the building panel 10, as discussed herein.

[0022] Referring to FIG.1, the present invention includes a building panel 10 having a first major exposed surface 11 opposite a second major exposed surface 12 that is opposite the upper major surface 11, and major side surfaces 13 that extend from the upper major surface 11 to the lower major surface 12 to form a perimeter of the building panel 10. The major side surfaces 13 may comprise first and second longitudinal side surfaces 41, 42 extending substantially parallel to each other. The major side surfaces 13 may further comprise first and second transverse side surfaces 31, 32 extending substantially parallel to each other. The first and second longitudinal side surfaces 41, 42 may extend substantially orthogonal to the first and second transverse side surfaces 31, 32.

[0023] The building panel 10 may have a panel thickness “tP” as measured from the upper major surface 11 to the lower major surface 12. The panel thickness tPmay range from about 25 mils to about 3,000 mils – including all values and sub-ranges there-between. In some embodiments, the panel thickness tP may range from about 25 mils to about 600 mils – including all values and sub- ranges there-between. In some embodiments, the panel thickness tPmay range from about 700 mils to about 2,000 mils – including all values and sub-ranges there-between.

[0024] The building panel 10 may have a panel length “LP” as measured from the first transverse side surface 31 to the second transverse side surface 32 – i.e., the distance along one of the first or second longitudinal side surfaces 41, 42. The panel length LPmay range from about 6 inches toAttorney Docket No. 22020-00-WO-01-ABP about 100 inches – including all values and sub-ranges there-between. The building panel 10 may have a panel width “WP” as measured from the first longitudinal side surface 41 to the second longitudinal side surface 42 – i.e., the distance along one of the first or second transverse side surfaces 31, 32. The panel width WPmay range from about 2 inches to about 60 inches – including all values and sub-ranges there-between. In some embodiments, the panel width WP may range from about 12 inches to about 60 inches – including all values and sub-ranges there-between.

[0025] The building panel 10 of the present invention comprises a body 100 having a coating 500 applied thereto. The body 100 may comprise a first major surface 111 opposite a second major surface 112 and a side surface 113 extending there-between. The body 100 may be formed from a cellulosic material (e.g., wood), metal, polymer, and combinations thereof. The body 100 may be formed from a single layer of material (also referred to as an integral structure) or the body 100 may have a laminate structure formed from at least two layers. As discussed in greater detail herein, the body 100 having a laminate structure may comprise one or more layers of a cellulosic layer 400, a substrate layer 200, and / or an adhesive layer 300. Although not pictured, the coating 500 of the present invention may be applied to a non-woven scrim. Non-limiting examples of non- woven scrim include fiberglass non-woven scrims. The non-woven scrim may form at least one of the first or second major surface 11, 12 of the building panel 10.

[0026] The building panel 10 may comprise a decorative pattern 30 that is visible from the upper major surface 11, the lower major surface 12, and / or the major side surface 13. The decorative pattern 30 may comprise a pattern formed from natural materials, such as cellulosic materials (e.g., wood grain, knots, burl, etc.) or a synthetic material such as a printed ink. The decorative pattern 30 may be a body decorative pattern that exists on one of the first major surface 111, second major surface 112, or side surface 113 of the body 100, whereby the body decorative pattern is visible through the coating 500.

[0027] The coating 500 may be independently applied to each of the first major surface 111, the second major surface 112, and / or the side surface 113 of the body 100. In a preferred embodiment, the coating 500 is applied to the first major surface 111 of the body 100 – as shown in FIG. 2. In another preferred embodiment, the coating 1500 may be applied to each of the first major surface 1111, the second major surface 1112, and the side surface 1113 of the body 1100 such that the coating 1500 encapsulates the body 100 – as shown in FIGS. 6 and 7.Attorney Docket No. 22020-00-WO-01-ABP

[0028] The coating 500 may be clear or substantially clear. For the purposes of this application, the phrases “substantially clear” or “substantially transparent” refers to materials that have the property of transmitting light in such a way that a normal, human eye (i.e., one belonging to a person with so-called "20 / 20" vision) or a suitable viewing device can see through the material distinctly. The level of transparency should generally be one which permits a normal, human eye to distinguish objects having length and width on the order of at least 0.5 inches, and should not significantly distort the perceived color of the original object. The coating 500 should be substantially clear (or substantially transparent) such that the underlying body decorative feature can be visible from the upper major surface 11 of the building panel 10 as the decorative pattern 30 on the overall building panel 10, as discussed further herein. The term “substantially clear” or “substantially transparent” may also refer to the coating having at least 70% optical clarity, whereby 100% optical clarity refers to an underlying surface being completely unhindered visually by the coating 500.

[0029] Referring now to FIG. 2, the coating 500 may comprises an upper coating surface 511 opposite a lower coating surface 512. The coating 500 may comprise a coating side surface 513 that extends from the upper coating surface 511 to the lower coating surface 512 and forms a perimeter of the coating 500. The coating side surface 513 may form a portion of the major side surface 13 of the building panel 10. Stated otherwise, the major side surface 13 of the building panel 10 may comprise the coating side surface 513. The coating 500 may have a coating thickness “tC” ranging from about 0.5 mils to about 3.0 mils – including all values and sub-ranges there- between – as measured from the upper coating surface 511 to the lower coating surface 512.

[0030] The coating 500 may comprise an inorganic composition that is substantially clear. According to the present invention, the phrase “inorganic composition” refers to a dry-state composition having less than 3 wt. % of organic compounds present based on the total dry-weight of the referenced inorganic composition, preferably less than 1.5 wt. % of organic compounds present based on the total dry-weight of the referenced inorganic composition. According to the present invention, the phrase “inorganic composition” may also refer to a wet-state composition that has less than 5.0 wt. % of organic compounds present based on the total wet-weight of the referenced inorganic composition, preferably less than 3.0 wt. % of organic compounds present based on the total wet-weight of the referenced inorganic composition.Attorney Docket No. 22020-00-WO-01-ABP

[0031] The phrase “dry-weight” refers to the weight of a referenced component or composition without the weight of any carrier. Thus, when calculating the amounts of components based on dry-weight, the calculation are to be based solely on the solid components (e.g., binder, filler, hydrophobic component, fibers, etc.) and should exclude any amount of residual carrier (e.g., water, VOC solvent) that may still be present from a wet-state, which will be discussed further herein. Additionally, according to the present invention, the phrase “dry-state” refers to a component or composition that is substantially free of carrier, as compared to the phrase “wet- state,” which refers to that component still containing various amounts of carrier. The term “weight-state” refers to a component or composition that further comprises a carrier. Similarly, the phrase “wet-weight” refers to a total weight of component or composition that includes the weight of the carrier when in the wet-state.

[0032] The inorganic composition may exhibit a high pH that ranges from about 9 to about 13 – including all pHs and sub-ranges there-between. In a preferred embodiment, the pH ranges from about 10 to less than about 13 – including all pHs and sub-ranges there-between. In a preferred embodiment, the pH is about 12.

[0033] The inorganic composition may comprise a silicate compound. Non-limiting examples of the silicate compound may include potassium silicate, tetraethyl orthosilicate, and combinations thereof.

[0034] The silicate compound may be present in an amount ranging from about 50 wt. % to about 98 wt. % - including all wt. % and sub-ranges there-between – based on the total weight of the inorganic composition in the dry-state. In a preferred embodiment, the silicate compound may be present in an amount ranging from about 70 wt. % to about 90 wt. % - including all wt. % and sub- ranges there-between – based on the total weight of the inorganic composition in the dry-state.

[0035] The inorganic composition may further comprise alumina trihydrate. The alumina trihydrate may be present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % - including all wt. % and sub-ranges there-between – based on the total weight of the inorganic composition in the dry-state. Additionally, compositions of the present invention may comprise a hydrate compound (e.g., alumina trihydrate), but that alone will not render that composition in a wet-state. Rather, the presence of water must be in a non-hydrate form (i.e., not bound in a crystalline matrix). A non-limiting example of composition being in the wet-state is the inorganicAttorney Docket No. 22020-00-WO-01-ABP composition of the present invention further comprises aqueous water – i.e., water acts as a solvent whereby the inorganic composition may be the solute.

[0036] The inorganic composition may optionally comprise other additives or fillers such as, but not limited to fire retarding compounds (also referred to as “flame retardant”), adhesion promoters, char-forming additives, viscosity modifying agents, dispersants, waxes, latex polymer, wetting agents, catalyst, cross-linkers, oxidizers, ultra-violet stabilizers.

[0037] According to some embodiments, the inorganic coating composition may further comprise organic compounds so long as the overall inorganic composition includes less than 5 wt. % of organic compounds in the overall inorganic composition. According to some embodiments, the inorganic composition may further comprise organic compounds so long as the overall inorganic composition includes less than 3 wt. % of organic compounds in the overall inorganic composition. According to some embodiments, the inorganic composition may further comprise organic compounds so long as the overall inorganic composition includes less than 2 wt. % of organic compounds in the overall inorganic composition. According to some embodiments, the inorganic composition may further comprise organic compounds so long as the overall inorganic composition includes less than 1.5 wt. % of organic compounds in the overall inorganic composition.

[0038] According to some embodiments, the inorganic composition may be substantially free of blowing-agent. The wetting agent may be present in a non-zero amount that is less than about 0.1 wt. % - based on the total dry-weight of the inorganic composition.

[0039] The filler may be present in the inorganic coating in an amount ranging from about 15 wt. % to about 75 wt. % - including all amounts and sub-range there-between – based on the total dry weight of the inorganic coating. Non-limiting examples of filler may include calcium carbonate (CaCO3), aluminum carbonate (Al2(CO3)3), lithium carbonate (LiCO3), magnesium carbonate (MgCO3), fumed silica, hectorite, aluminum oxide (Al2O3), and combinations thereof.

[0040] The flame retardants may be present in the coating 500 in an amount ranging from about 0 wt. % to about 50 wt. % – including all values and sub-ranges there-between – based on the total weight of the coating 500. Non-limiting examples of flame retardant may include ammonium hydroxide, magnesium hydroxide, huntite, hydromagnesite, silica, polyphosphate, chloride salts – such as sodium chloride, antimony oxide, and borates, such as calcium borate, magnesium borate, zinc borate, and combinations thereof.Attorney Docket No. 22020-00-WO-01-ABP

[0041] The dispersant may be ionic or non-ionic. Non-limiting examples of ionic dispersant includes sodium polyacrylate. Non-limiting examples of non-ionic dispersant include propoxylated ethoxylated linear alcohol, ethoxylated nonylphenols, ethoxylated alcohols, ethoxylated castor oil, polyethylene glycol fatty acid esters, and ethyleneglycol-propyleneglycol copolymers. The dispersant may be present in the inorganic composition in an amount that ranges from a non-zero amount to less than 1 wt. % based on the total dry-weight of the inorganic composition. In a preferred embodiment, the dispersant is preset in an amount ranging from a non- zero amount to less than 0.5 wt. % based on the total dry-weight of the inorganic composition.

[0042] The inorganic coating composition may further comprise a thickener. In a non-limiting embodiment, the thickener may be selected from one or more of magnesium aluminosilicate, potassium silicate, diatomaceous earth, hydrophilic fumed silica, hydrophobic modified alkali swellable emulsions, and combinations thereof. In some embodiments, the thickener is magnesium aluminosilicate.

[0043] The thickener may be present in an amount ranging from about 0.1 wt. % to about 20.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the thickener may be present in an amount ranging from about 0.4 wt. % to about 15.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the thickener may be present in an amount ranging from about 0.7 wt. % to about 12.0 wt. % based on the total dry- weight of the inorganic coating – including all wt. % and sub-ranges there-between.

[0044] In some embodiments, the thickener may comprise magnesium aluminosilicate in an amount ranging from about 0.8 wt. % to about 2.7 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the thickener may comprise magnesium aluminosilicate in an amount of about 0.9 to about 1.0 wt. % based on the total dry-weight of the inorganic coating.

[0045] In some embodiments, the thickener may comprise hectorite in an amount ranging from about 4.0 wt. % to about 10.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between.

[0046] In some embodiments, the thickener may comprise hydrophobic fumed silica in an amount ranging from about 0.5 wt. % to about 2.5 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the thickenerAttorney Docket No. 22020-00-WO-01-ABP may comprise hydrophobic fumed silica in an amount of about 1.2 to about 1.8 wt. % based on the total dry-weight of the inorganic coating.

[0047] In some embodiments, the thickener may comprise diatomaceous earth in an amount ranging from about 0.5 wt. % to about 4.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the thickener may comprise diatomaceous earth in an amount of about 1.0 to about 3.0 wt. % based on the total dry-weight of the inorganic coating.

[0048] The inorganic coating composition may further comprise a sealant component. In a non- limiting embodiment, the sealant component may an alkali siliconate compound. The alkali siliconate compound may be selected from one or more of sodium methyl siliconate, potassium methyl siliconate, and combinations thereof.

[0049] The sealant component may be present in an amount ranging from about 9.0 wt. % to about 20.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub- ranges there-between. In some embodiments, the sealant component may be present in an amount ranging from about 9.0 wt. % to about 13.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there-between. In some embodiments, the sealant component may be present in an amount ranging from about 12.0 wt. % to about 14.0 wt. % based on the total dry-weight of the inorganic coating – including all wt. % and sub-ranges there- between.

[0050] The sealant component may be present in an amount ranging from about 9.0 wt. % to about 17.0 wt. % based on the total wet-weight of the inorganic coating – including all wt. % and sub- ranges there-between. In some embodiments, the sealant component may be present in an amount ranging from about 15.0 wt. % to about 17.0 wt. % based on the total wet-weight of the inorganic coating – including all wt. % and sub-ranges there-between.

[0051] The coating 500 may be applied in an amount ranging from about 12 g / ft2to about 24 g / ft2on the body 100 in the wet-state – including all application amounts and sub-ranges there-between. The coating 500 may be present in the building panel 10 in an amount ranging from about 4.2 g / ft2to about 19.2 g / ft2on the body 100 in the dry-state – including all application amounts and sub- ranges there-between.Attorney Docket No. 22020-00-WO-01-ABP

[0052] According to the present invention, the coating 500 may be comprised of a single integral layer (FIG. 2) or a plurality of sub-layers 550, 560 (FIG. 3). The coating 500 show in FIG. 2 having a single integral layer comprises the inorganic composition of the present invention.

[0053] Referring now to FIG. 3, the coating 500 of the present invention may comprise may comprise a first sub-layer 550, whereby the first sub-layer 550 is directly atop one or more of the first major surface 111, second major surface 112, and / or side surface 113 of the body 100. The second sub-layer 560 may be directly atop the first sub-layer 550. The first sub-layer 550 may comprise the inorganic composition of the present invention. In such embodiments, the inorganic composition may be present in an amount ranging from about 95 wt. % to about 100 wt. % – including all values and sub-ranges there-between – based on the total dry-weight of the first sub- layer 550.

[0054] The second sub-layer 560 of FIG. 3 may comprise a topcoat. The second sub-layer 560 may be an organic coating. The second sub-layer 560 may comprise polymer binder capable for forming a topcoat layer atop the underlying body 100. The second sub-layer 560 may be formed from a moisture barrier composition that imparts moisture barrier properties to the resulting first sub-layer 550. The second sub-layer 560 may be present in an amount ranging from about 2.0 g / ft2to about 5.5 g / ft2– including all amounts and sub-ranges there-between – based on the total dry-weight of the second sub-layer 560. During manufacture of the building panel 10, the second sub-layer 560 may be applied in an amount ranging from about 6.0 g / ft2to about 12.0 g / ft2– including all amounts and sub-ranges there-between – based on the total wet-weight of the second sub-layer 560.

[0055] The second sub-layer 560 may further comprise various additives and fillers. The polymer binder may be present in an amount ranging from about 85 wt. % to about 99.9 wt. % – including all values and sub-ranges there-between – based on the total weight of the second sub-layer 560 in the dry-state.

[0056] The polymer binder may comprise one or more vinyl or acrylic homopolymers or copolymers formed from ethylenically unsaturated monomers such as ethylene or butadiene and vinyl monomers such as styrene, vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrates, acrylic acid, methacrylic acid, or esters of acrylic acid and / or esters of methacrylic acid. The esters of acrylic or methacrylic acid may have an alkyl ester portion containing 1 to 12 carbon atoms as well as aromatic derivatives of acrylic and methacrylic acid, and can include, for example,Attorney Docket No. 22020-00-WO-01-ABP acrylic and methacrylic acid, methyl acrylate and methyl methacrylate, ethyl acrylate and ethyl methacrylate, butyl acrylate and butyl methacrylate, propyl acrylate and propyl methacrylate, 2- ethyl hexyl acrylate and 2-ethyl hexyl methacrylate, cyclohexyl acrylate and cyclohexyl methacrylate, decyl acrylate and decyl methacrylate, isodecyl acrylate and isodecyl methacrylate, benzyl acrylate and benzyl methacrylate and various reaction products such as butyl, phenyl, and cresyl glycidyl ethers reacted with acrylic and methacrylic acids.

[0057] Specifically, the hydrophobic polymer may be a homopolymer or copolymer produced from ethylenically unsaturated monomers, such as styrene, alpha-methylstyrene, vinyl toluene, ethylene, propylene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, acrylamide, methacrylamide, acrylic acid, methacrylic acid, (meth)acryloxy-propionic acid, itaconic acid, aconitic acid, maleic acid, monomethyl maleate, monomethyl fumarate, monomethyl itaconate, various (C1-C2o) alkyl or (C3-C20) alkenyl esters of (meth)acrylic acid and the like. The expression (meth)acrylic, as used herein, is intended to serve as a generic expression embracing both acrylic and methacrylic acid and esters thereof e.g., methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, isobutyl (meth)acrylate, 2-ethyl hexyl(meth)acrylate, benzyl (meth)acrylate, lauryl (meth)acrylate, oleyl (meth)acrylate, palmityl (meth)acrylate, stearyl (meth)acrylate and the like. In other embodiments, the hydrophobic polymeric binder may include polymer comprising polyurethane, polyester, polyester-modified polyurethane, epoxy or a combination thereof.

[0058] The hydrophobic polymer may be present in an amount ranging from about 70 wt. % to about 100 wt. % - including all values and sub-ranges there-between – based on the total weight of the moisture barrier composition.

[0059] Generally, the coating 500 may be applied directly to one of the first major surface 111, the second major surface 112, and / or the side surface 113 of the body 100, optionally with the addition of a carrier such as water. Each of the first sub-layer 550 and / or the second sub-layer 560 may each be applied in the wet-state, whereby the carrier is selected from water, VOC-based solvent, and combinations thereof. The inorganic coating of the second sub-layer 550 may be applied in the wet-state, whereby the carrier is water and is substantially free of VOC-based solvent.

[0060] The coating 500 – including each sub-layer 550, 560 – may be applied by spray, roll- coating, dip coating, curtain coating, brushing, blade coating, or the like, followed by drying and / or curing (optionally with the addition of heat) for a period of time to form the coating 500 atop atAttorney Docket No. 22020-00-WO-01-ABP least one of the first major surface 111, the second major surface 112, and / or the side surface 113 of the body 100 – as discussed in greater detail herein.

[0061] Between each application of sub-layers 550, 560 in the wet-state, there may be a period of drying time before a subsequent layer is applied in the wet state. In a non-limiting example, the first sub-layer 550 may be applied followed by a period of time for drying the first sub-layer 550 from the wet-state to the dry state, whereby subsequently the second sub-layer 560 is applied in the wet-state to the first sub-layer 550 that is in the dry state.

[0062] The coating 500 may be applied in the wet-state directly to at least one of the first major surface 111, second major surface 112, and / or side surface 113 of the body 100. In the wet-state, the first sub-layer 550 may comprise a carrier in an amount ranging from about 50 wt. % to about 85 wt. % – including all values and sub-ranges there-between – based on the total weight of the wet-state coating 500. In some embodiments, the first sub-layer 550 may be applied in a wet-state having a solids content of about 35% to about 40 % - including all percentages and sub-ranges there-between. In some embodiments, the first sub-layer 550 may be applied in a wet-state having a solids content of about 35% to about 38 % - including all percentages and sub-ranges there- between.

[0063] In the wet-state, the coating 500 may be applied in an amount ranging from about 6 / ft2to about 12 g / ft2– based on the total weight of the coating 500 in the wet-state – including all application amounts and sub-ranges there-between.

[0064] In a preferred embodiment, the wet-state sealant composition is a waterborne system having a carrier of water and a low VOC (i.e., volatile organic compound) content – i.e. substantially free of VOC solvents. The coating 500 in the wet-state may then be cured or dried (optionally with the addition of heat) for a first time period, thereby forming the coating 500 atop the body 100.

[0065] Referring to FIG. 3, the resulting first sub-layer 550 may comprise a first sub-layer upper surface 551 and a first sub-layer lower surface 552 opposite the first sub-layer upper surface 551. The first sub-layer 550 may have a first sub-layer thickness “tC1” as measured from the first sub- layer upper surface 551 to the first sub-layer lower surface 552 – the first sub-layer thickness tC1 being a positive non-zero value. The first sub-layer 550 may comprise a first sub-layer side surface 553 that extends from the first sub-layer upper surface 551 to the first sub-layer lower surface 552 and forms a perimeter of the first sub-layer 550.Attorney Docket No. 22020-00-WO-01-ABP

[0066] Referring to FIGS. 2-4, the body 100 may be formed from a cellulosic material, which comprises pores. Thus, once the coating 500 is applied to one of the first major surface 111, second major surface 112, and / or side surface 113 of the body 100, at least a portion of the coating 500 – including the first sub-layer 550 for the embodiments of FIG. 3 – may penetrate into the pores the cellulosic material in a direction extending from one of the first major surface 111, second major surface 112, and / or side surface 113 of the body 100 toward the center of the body 100.

[0067] Referring to FIG. 3, the second sub-layer 560 may be formed by directly applying the previously discussed inorganic composition in the wet-state to the first sub-layer upper surface 551 of the first sub-layer 550 which is in the dry-state. In the wet-state, the second sub-layer 560 may be applied in an amount ranging from about 6 gft2to about 12 g / ft2– including all values and sub-ranges there-between.

[0068] The second sub-layer 560 may have a second sub-layer thickness “tC2” as measured from the second sub-layer upper surface 561 to the second sub-layer lower surface 562. The second sub-layer thickness tC2may be a positive, non-zero value. The second sub-layer 560 may comprise a second sub-layer side surface 563 that extends from the second sub-layer upper surface 561 to the second sub-layer lower surface 562 and forms a perimeter of the second sub-layer 560.

[0069] The first sub-layer side surface 553 and the second sub-layer side surface 563 may form at least a portion of the coating side surface 513. Stated otherwise, the coating side surface 513 may comprise the first sub-layer side surface 553 and the second sub-layer side surface 563.

[0070] The overall coating thickness tCof coating 500 may be the summation of the first sub-layer thickness tC1and the second sub-layer thickness tC2– as follows: tC = tC1 + tC2

[0071] According to these embodiments, the first sub-layer lower surface 552 of the first sub-layer 550 may directly contact one of the first major surface 111, the second major surface 112, and / or the side surface 113 of the body 100. The first sub-layer upper surface 551 may contact the second sub-layer lower surface 562 of the second sub-layer 550. The second sub-layer upper surface 561 may form at least part of the upper coating surface 511 of the coating 500. The first sub-layer lower surface 552 may form at least part of the lower coating surface 512 of the coating 500. The second sub-layer upper surface 561 may form at least part of the upper major surface 11 of the building panel 10.Attorney Docket No. 22020-00-WO-01-ABP

[0072] Referring now to FIGS. 2 and 3, the body 100 may comprise a cellulosic layer 400, whereby the coating 500 is applied directly to the cellulosic layer 400. In other embodiments where the body 100 may be a laminate structure comprising multiple layers that includes a cellulosic layer 400 atop a substrate layer 200 with an adhesive layer 300 positioned there-between. The body 100 may also comprise the substrate layer 200 without the cellulosic layer 400 or adhesive layer 200, whereby the coating 500 is applied to at least one surface of the substrate layer 200 – as discussed further herein.

[0073] Referring to FIG. 2, the cellulosic layer 400 may comprise an upper cellulosic surface 411 and a lower cellulosic surface 412 opposite the upper cellulosic surface 411. The cellulosic layer 400 may comprise a cellulosic side surface 413 that extends from the upper cellulosic surface 411 to the lower cellulosic surface 412 and forms a perimeter of the cellulosic layer 400. The cellulosic side surface 413 may form a portion of the side surface 113 of the body 100. Stated otherwise, the side surface 113 of the body 100 may comprise the cellulosic side surface 413. The side surface 113 of the body 100 may form a major side surface 13 of the building panel 10. The first major surface 111 of the body 100 may comprise the upper cellulosic surface 411.

[0074] The cellulosic layer 400 may have a cellulosic layer thickness “tCL” as measured by the distance between the upper and lower cellulosic surfaces 411, 412. The cellulosic layer thickness tCL may range from about 10 mils to about 3,000 mils – including all values and sub-ranges there- between. In some embodiments, the cellulosic layer 400 may form a veneer that is bonded to the substrate layer 200 by the adhesive layer 300, whereby the cellulosic thickness tCLmay range from about 10 mils to about 100 mils – including all values and sub-ranges there-between. In other embodiments, the cellulosic layer 400 may form the entirety of the body 100, whereby the cellulosic thickness tCL may range from about 300 mils to about 3,000 mils – including all values and sub-ranges there-between.

[0075] The cellulosic layer 400 may be formed from a cellulosic material such as wood, bamboo, and a combination thereof, and may be naturally occurring or engineered. Non-limiting examples of wood include cherry, maple, oak, walnut, pine, poplar, spruce, chestnut, mahogany, rosewood, teak, ash, hickory, beech, birch, cedar, fir, hemlock, basswood, alder wood, obeche wood, and combinations thereof. The cellulosic layer 400 may comprise pores that are not only present within the body of the cellulosic layer 400 but also exposed on at least one of the upper cellulosic surface 411, lower cellulosic surface 412, and / or the cellulosic side surface 413. The porosity of theAttorney Docket No. 22020-00-WO-01-ABP cellulosic layer 400 will depend on the bamboo or type of wood selected as the material that forms the cellulosic layer 400.

[0076] The benefit of using a cellulosic layer 400 is that the resulting building panel 10 will exhibit authentic decorative features 30 of real wood and / or bamboo (e.g., wood grain, knots, burl, etc.) while minimizing the overall thickness required for the building panel 10 without necessitating artificial print layers. Artificial print layers, such as those on various papers or plastics, have been used as a way to recreate wood grain, knots, burl, etc., while minimizing layer thickness. Such print layers, however, are undesirable because of the limited amount of variation the cellulosic pattern across a large number of panels as compared to the same large number of panels that use cellulosic layers formed from real wood and / or bamboo. Stated otherwise, artificial print layers are not preferred because of the repetition in the decorative pattern over large installation areas.

[0077] Although not limited to this embodiment, the coating 500 may be directly atop the upper cellulosic surface 411, the lower cellulosic surface 412, and / or the cellulosic side surface 413 of the cellulosic layer 400. The coating 500 may be applied to the cellulosic layer 400 such that the lower coating surface 512 is in direct contact with the upper cellulosic layer surface 412. In such embodiments, the lower coating surface 512 may directly contact the upper cellulosic surface 411, such that the upper coating surface 511 forms at least a portion of the upper major surface 11 of the building panel 10.

[0078] Referring now to FIG. 2, according to some embodiments of the present invention the building panel 10 may include cellulosic layer 400 being adhesively bonded to the substrate layer 200 by an adhesive layer 300. The combination of layers 200, 300, 400, 500 of the present invention creates a laminate structure having high lamination integrity in a ceiling system under both standard conditions (i.e. daily operation of an interior building environment) but also during exposure to the extreme heat and temperature that may result from a fire.

[0079] The substrate layer 200 may comprises an upper substrate surface 211 and a lower substrate surface 212 that is opposite the upper substrate surface 211. The substrate layer 200 may comprise a substrate side surface 213 that extends from the upper substrate surface 211 to the lower substrate surface 212 and forms a perimeter of the substrate layer 200. The substrate side surface 213 may form a portion of the side surface 113 of the body 100. Stated otherwise, the side surface 113 of the body 100 may comprise the substrate side surface 213.Attorney Docket No. 22020-00-WO-01-ABP

[0080] The substrate layer 200 may be formed from a metallic material, ceramic material, or composite material. Non-limiting examples of metallic material include aluminum, steel, and iron. In a preferred embodiment, the substrate layer 200 is formed from aluminum. The substrate layer 200 may have a substrate thickness “tS” ranging from about 20 mils to about 100 mils – including all values and sub-ranges there-between. The substrate thickness tS may range from about 25 mils to about 80 mils. In a preferred embodiment, the substrate thickness tS ranges from about 30 mils to about 65 mils – including all values and sub-ranges there-between.

[0081] The adhesive layer 300 may comprises an upper adhesive surface 311 and a lower adhesive surface 312 opposite the upper adhesive surface 311. The adhesive layer 300 may comprise an adhesive side surface 313 that extends from the upper adhesive surface 311 to the lower adhesive surface 312 and forms a perimeter of the adhesive layer 300. The adhesive side surface 313 may form a portion of the side surface 113 of the body 100. Stated otherwise, the side surface 113 of the body 100 may comprise the adhesive side surface 213. The adhesive layer 300 may have an adhesive thickness “tA” ranging from about 2 mils to about 20 mils – including all values and sub- ranges there-between – as measured from the upper adhesive surface 311 to the lower adhesive surface 312. In a preferred embodiment, the adhesive thickness tA ranges from about 5 mils to about 15 mils – including all values and sub-ranges there-between.

[0082] According to embodiments where the building panel 10 has the laminate structure, the overall panel thickness tP of the building panel 10 may be the summation of the substrate thickness tS, the adhesive thickness tA, the cellulosic layer thickness tCL, and the coating thickness tCas follows: tP = tS + tA + tCL +tC

[0083] The upper substrate surface 211 of the substrate layer 200 may directly contact the lower adhesive surface 312 of the adhesive layer 300 and the upper adhesive surface 311 of the adhesive layer 300 may directly contact the lower cellulosic surface 412 of the cellulosic layer 400 such that the adhesive layer 300 adhesively bonds together the cellulosic layer 400 and the substrate layer 200. The lower coating surface 512 may directly contact the upper cellulosic surface 411, such that the upper coating surface 511 forms at least a portion of the upper major surface 11 of the building panel 10. In such embodiments, the lower substrate surface 212 may form at least a portion of the lower major surface 12 of the building panel 10.Attorney Docket No. 22020-00-WO-01-ABP

[0084] The adhesive layer 300 may be formed from an adhesive composition that is a hot-melt composition, water-based polyvinyl acetate adhesive, and combinations thereof. According to the purposes of the present invention, the term “hot-melt adhesive composition” means a composition having a melt viscosity that ranges from about 10,000 centipoise to about 40,000 centipoise at a temperature of about 275 °F – including all values and sub-ranges there-between. The hot-melt adhesive composition may be solid at room temperature and be substantially free of solvent. The adhesive composition may comprise adhesive polymer in an amount ranging from about 50 wt. % to about 100 wt. % based on the total weight of the adhesive composition – including all values and sub-ranges there-between.

[0085] The adhesive polymer according to the present invention may be a thermoplastic polymer. Non-limiting examples of the thermoplastic polymer may include moisture cured polyester modified polyurethane polymers. Such polyester modified polyurethanes may be formed by reacting organic diisocyanate with difunctional polyester polyol and low molecular weight diols (as chain-extending agents) at a non-limiting NCO:OH ratio of about 0.7:1 to about 1.3:1 – including all sub-ranges and ratios there-between.

[0086] Non-limiting examples of polyester polyol include di-functional polyester diols containing alcoholic hydroxyl groups. Suitable polyester diols are polyester having average molecular weights of from 800 to 5000 and preferably from 2000 to 4000 produced from (i) dicarboxylic acids containing at least 6 carbon atoms, such as adipic acid, pimelic acid, suberic acid, azelaic acid and / or sebacic acid (preferably adipic acid, as the sole acid component) and (ii) alkane diols that may contain at least 4 carbon atoms, such as, for example, 1,4-dihydroxy-butane, 1,5- dihydroxypentane and / or 1,6-dihydroxy-hexane. Polycondensates of ω-hydroxyalkane-mono- carboxylic acids and the polymers of their lactones are also suitable, although less preferred.

[0087] Low molecular weight diols suitable as chain-extending agents in accordance with the present invention include, in particular, aliphatic diols having average molecular weight of from 62 to 400 or mixtures thereof. Non-limiting examples of such diols include ethylene glycol, 1,3- dihydroxy-propane, 1,4-dihydroxy-butane, 1,5-dihydroxypentane, 1,6-dihydroxyhexane, and the like.

[0088] Non-limiting examples of suitable aromatic polyisocyanates include all isomers of toluylene-diisocyanate (TDI), naphthalene-1,5-diisocyanate, diphenylmethane-4,4′-diisocyanate (MDI), diphenylmethane-2,4′-diisocyanate and mixtures of 4,4′-diphenylmethane-diisocyanateAttorney Docket No. 22020-00-WO-01-ABP with the 2,4′ isomer or mixtures thereof with oligomers of higher functionality (so-called crude MDI), xylylene-diisocyanate (XDI), 4,4′-diphenyl-dimethylmethane-diisocyanate, di- and tetra- alkyl-diphenylmethane-diisocyanate, 4,4′-dibenzyl-diisocyanate, 1,3-phenylene-diisocyanate and 1,4-phenylene-diisocyanate. Examples of suitable cycloaliphatic polyisocyanates are the hydrogenation products of the above-mentioned aromatic diisocyanates, such as 4,4′- dicyclohexylmethane-diisocyanate (H12MDI), 1-isocyanatomethyl-3-isocyanato-1,5,5-trimethyl- cyclohexane (isophorone-diisocyanate, IPDI), cyclohexane-1,4-diisocyanate, hydrogenated xylylene-diisocyanate (H6XDI), 1-methyl-2,4-diisocyanato-cyclohexane, m- or p- tetramethylxylene-diisocyanate (m-TMXDI, p-TMXDI) and dimer-fatty acid diisocyanate. Examples of aliphatic polyisocyanates are tetramethoxybutane-1,4-diisocyanate, butane-1,4- diisocyanate, hexane-1,6-diisocyanate (HDI), 1,6-diisocyanato-2,2,4-trimethylhexane, 1,6- diisocyanato-2,4,4-trimethylhexane and 1,2-dodecane-diisocyanate (C12DI).

[0089] The adhesive composition of the present invention may further comprise additives selected from the group consisting of 2,2′-dimorpholinethyl ether catalyst, di(2,6- dimethylmorpholinoethyl)ether catalyst, adhesion promoters, diluents, plasticizers, fillers, antioxidants pigments, UV absorbers and combinations thereof. Non-limiting example of pigment include iron oxide (such as a red pigment).

[0090] In other embodiments, the adhesive composition may further comprise a flame retardant. Non-limiting examples of flame retardant may include ammonium hydroxide, magnesium hydroxide, huntite, hydromagnesite, silica, polyphosphate, melamine cyanurate, chloride salts – such as sodium chloride, antimony oxide, and borates, such as calcium borate, magnesium borate, zinc borate, and combinations thereof.

[0091] The flame retardant may be present in the adhesive composition in an amount ranging from about 0 wt. % to about 50 wt. % based on the total weight of the adhesive composition – including all values and sub-ranged there-between.

[0092] Each of the coating 500 of FIGS. 1 and 2, as well as the sub-layers 550, 560 may be individually applied by spray, roll-coating, dip coating, curtain coating, brushing, blade coating, or the like.

[0093] According to the present invention, the coating 500 applied to the cellulosic layer 400 provides an aesthetically pleasing building panel 10 such that the decorative features 30 of the cellulosic layer are visible from the upper major surface 11 of the building panel 10 because theAttorney Docket No. 22020-00-WO-01-ABP decorative coating 500 is substantially clear. Furthermore, the inorganic composition of the coating 500 helps provide an insulative heat-barrier to the cellulosic layer 400, thereby helping prevent the cellulosic layer 400 from igniting during a fire and propagating through the building panel 10.

[0094] Referring to FIG. 4, the building panel 10 of the present invention may be a ceiling panel (as shown installed in the ceiling system of FIG. 4), a wall panel, or the like. The lower major surface 12 of the ceiling panel 10 of the present invention may face the plenum space 3 of an interior space of a ceiling system 1. The upper major surface 11 of the ceiling panel 10 of the present invention may face the active space 2 of an interior space of a ceiling system 1.

[0095] In non-exemplified embodiments, the present invention may include a building panel having an upper major surface opposite a lower major surface, the building panel comprising a cellulosic layer (also referred to as “cellulosic body” in this embodiment) and a coating. The cellulosic body is self-supporting and comprises an upper cellulosic surface and a lower cellulosic surface opposite the upper cellulosic surface. Non-limiting examples of a cellulosic body may include MDF board, wooden planks, or the like. The cellulosic body may have a cellulosic body thickness as measured from the lower cellulosic surface to the upper cellulosic surface that ranges up to about 3 inches – including all values and sub-ranges there-between.

[0096] The building panel 10 of such embodiments may have the coating 500 applied to at least one of the upper cellulosic surface 411 or the lower cellulosic surface 412 of the cellulosic layer 400. The coating 500 comprises an upper coating surface 511 opposite a lower coating surface 512, whereby the lower coating surface 512 of the coating 500 may directly contact the upper cellulosic surface 411 of the cellulosic body 400. The coating 500 comprises at least the second sub-layer 560 and optionally the first sub-layer 550, as previously discussed. The upper major surface 11 of the building panel 10 may comprise the upper coating surface 511 of the coating 500. According to some embodiments, the lower major surface 12 of the building panel 10 may be uncoated, whereby the lower major surface 12 of the building panel 10 does not comprise the coating 500, but rather the lower cellulosic surface 412 or the lower substrate surface 212.

[0097] The following examples are prepared in accordance with the present invention. The present invention is not limited to the examples described herein. EXAMPLESAttorney Docket No. 22020-00-WO-01-ABP

[0098] The following experiments tested subjected various coatings to a measure of viscosity as well as the color, gloss, mechanical, and hydrophobicity performance of the resulting coating. The coating formulation included the following components:

[0099] Si 1: alkali siliconate (sodium methyl siliconate)

[0100] Si 2: alkali siliconate (potassium methyl siliconate)

[0101] Si 3: phenylmethyl polsiloxane resin

[0102] Additional Component: including pigments, non-ionic wetting agent, and non-ionic emulsifying agent, dispersant, wax. The pigment includes iron oxide. The coating formulations are set forth in Table 1. Table 1 Wt. % Ex. 1 Ex. 2Comp.Comp. Ex. 1Ex. 2 %

[0103] As demonstrated by Table 1 – the coating formulations comprising the alkali siliconate sealer (i.e., potassium siliconate, sodium siliconate) exhibited a viscosity reaching the desired performance (i.e., between about 1,000 cps to about 2,000 cps at 10 RPM) – such result is surprising when compared against other silicon sealer (i.e., phenylmethyl polsiloxane resin) that included the same thickener in the same amounts, yet exhibited an undesirable viscosity (i.e.,Attorney Docket No. 22020-00-WO-01-ABP above 2,000 cps at 10 RPM). The coating of Comparative Example 2 also resulted in a failing analysis as the viscosity recorded was well below the acceptable threshold (i.e., only 108 cps).

[0104] A number of coating applications based on each formulation of Examples 1 and 2 as well as Comparative Examples 1 and 2 were then applied to a cellulosic substrate. The details of each coatings are set forth below in Table 2.Attorney Docket No.22020-00-WO-01-ABP Table 2 La LaC G CrosP HarWat 1 5 1 C Consi G CraPerformancePass Pass Pass Pass N / A N / A Fail FailAttorney Docket No. 22020-00-WO-01-ABP

[0105] The application amounts listed in Table 2 are shown in the wet-state.

[0106] As demonstrated by Table 2 – the coating formulation of the present invention provided a surprisingly improvement in aesthetic characteristics without sacrificing water-drop performance. Specifically, Coatings 2 and 4 – which include a single layer of the inventive coating formulation used in combination with a top coat – resulted in gloss values of less than 4 as compared to the gloss values of Coatings 6 and 8 – both of which are 7.8 or greater, while still exhibiting a tight bead water drop performance for the first 5 hours.

[0107] More surprisingly, the coating formulation of Examples 1 and 2 exhibited desirable cross- hatch strength while the coating of Comparative Example 1, which uses phenylmethyl polsiloxane resin – resulted in inferior cross hatch strength.

[0108] The Coatings 1-4 also exhibits a passing grade performance for cracking test while the control coating exhibited a failing grade. The crack testing was performed by a visual assessment of each coating after a 24 hour period exposed to a temperature of at 130 °F – whereby a passing grade was assigned to coatings exhibiting no cracks or only minor cracking (minor spots that do not overlap about the face of the coating) while a failing grade was assigned to coatings exhibit elongated cracking (cracks having aspect ratios of greater than 10:1), which overlap adjacent cracks.

[0109] A first study was also performed to test the impact of magnesium aluminosilicate within the coating system – whereby a number of formulations were tested, each having varying amounts of the magnesium aluminosilicate set forth above in Table 1. The viscosity of each coating formulation was measured a first time initially and a second time 24 hours later. The results are set forth below in Table 3. Table 3 Viscosity Magnesium Viscosity AfterAttorney Docket No. 22020-00-WO-01-ABP Ex. 11 2.0 wt. % 4.0 4.67 Ex. 12 5.0 wt. % 6.67 8.0

[0110] As demolicate in an amount ranging from 0.1 wt. % to about 5 wt. % resulted in an initial viscosity within an acceptable threshold (about 2.6 to 6.7 cps @ 60 RPM for #2). More specifically, the magnesium aluminosilicate in an amount ranging from about 0.5 wt. % to about 5.0 wt. % provided a superior viscosity performance in that both the starting viscosity and viscosity after 24 hours were stable and within the highly desirable viscosity range.

[0111] A second study was also performed to test the hectorite within the coating system – whereby a number of formulations were tested, each having varying amounts of the hectorite set forth above in Table 1. The viscosity of each coating formulation was measured a first time initially and a second time 24 hours later. The results are set forth below in Table 4. Table 4 Viscosity Hectorite #5 @ 50 )

[0112] As demonstrated by Table 4 – surprisingly, the hectorite in an amount ranging from 1.0 wt. % to about 3.0 wt. % resulted in an initial viscosity within an acceptable threshold (about >1,500 up to 24,000 cps @ 50 RPM for #5) –whereby outside of these ranges, resulted in unacceptable viscosities (either too low, such as 0.0 or too high, which resulted in error values).

Claims

Attorney Docket No. 22020-00-WO-01-ABP CLAIMS WHAT IS CLAIMED IS:

1. A flame-retardant building panel comprising: a body having a first major surface opposite a second major surface; an inorganic coating comprising: a silicate compound; an alkali siliconate compound; a thickener comprising magnesium aluminosilicate; and wherein the coating is atop the first major surface of the body.

2. The flame-retardant building panel according to claim 1, wherein the first major surface of the body is wood.

3. The flame-retardant building panel according to any one of claims 1 to 2, wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

4. The flame-retardant building panel according to any one of claims 1 to 3, wherein the silicate compound is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the inorganic coating.

5. The flame-retardant building panel according to any one of claims 1 to 4, wherein the alkali siliconate compound is selected from the group consisting of sodium methyl siliconate, potassium methyl siliconate, and combinations thereof.

6. The flame-retardant building panel according to any one of claims 1 to 5, wherein the alkali siliconate compound is present in an amount ranging from about 9.0 to about 20.0 wt. % based on the total weight of the inorganic coating.Attorney Docket No. 22020-00-WO-01-ABP 7. The flame-retardant building panel according to any one of claims 1 to 6, wherein the magnesium aluminosilicate is present in an amount ranging from about 0.5 wt. % to about 2.0 wt. % based on the total weight of the inorganic coating.

8. The flame-retardant building panel according to any one of claims 1 to 7, wherein the inorganic coating further comprises a dispersant.

9. The flame-retardant building panel according to claim 8, wherein the dispersant is present in an amount ranging from a non-zero value up to about 1.5 wt. % based on the total weight of the inorganic coating.

10. The flame-retardant building panel according to any one of claims 1 to 9, wherein the inorganic coating has a solids content of at least 99 wt. % based on the total weight of the inorganic coating.

11. The flame-retardant building panel according to any one of claims 1 to 10, wherein the coating comprises organic components in a non-zero amount up to about 2 wt. % based on the total weight of the inorganic coating.

12. The flame-retardant building panel according to claim 11, wherein the organic component is selected from the groups consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

13. The flame-retardant building panel according to any one of claims 1 to 12, wherein the inorganic coating is present in an amount ranging from about 4.2 g / ft2to about 20 g / ft2.

14. The flame-retardant building panel according to any one of claims 1 to 13, wherein the inorganic coating further comprises aluminum hydroxide.

15. The flame-retardant building panel according to claim 14, wherein the aluminum hydroxide is present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % based on the total weight of the inorganic coating.Attorney Docket No. 22020-00-WO-01-ABP 16. The flame-retardant building panel according to any one of claims 1 to 15, wherein the thickener further comprises one or more of hectorite, hydrophobic fumed silica, diatomaceous earth, hydrophobic modified alkali swellable emulsion, and combinations thereof.

17. The flame-retardant building panel according to any one of claims 1 to 16, further comprising a top coat applied to an upper surface of the inorganic coating.

18. A flame-retardant building panel comprising: a cellulosic body having a first major surface opposite a second major surface; an inorganic coating comprising: a silicate compound; an alkali siliconate compound; a thickener; and wherein the inorganic coating is atop the first major surface of the cellulosic body.

19. The flame-retardant building panel according to claim 18, wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

20. The flame-retardant building panel according to any one of claims 18 to 19, wherein the silicate compound is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the inorganic coating.

21. The flame-retardant building panel according to any one of claims 18 to 20, wherein the alkali siliconate compound is selected from the group consisting of sodium methyl siliconate, potassium methyl siliconate, and combinations thereof.

22. The flame-retardant building panel according to any one of claims 18 to 21, wherein the alkali siliconate compound is present in an amount ranging from about 9.0 wt. % to about 20.0 wt. % based on the total weight of the inorganic coating.Attorney Docket No. 22020-00-WO-01-ABP 23. The flame-retardant building panel according to any one of claims 18to 22, wherein the coating further comprises a dispersant.

24. The flame-retardant building panel according to claim 23, wherein the dispersant is present in an amount ranging from a non-zero value up to about 1.5 wt. % based on the total weight of the inorganic coating.

25. The flame-retardant building panel according to any one of claims 18 to 24, wherein the inorganic coating has a solids content of at least 99 wt. % based on the total weight of the inorganic coating.

26. The flame-retardant building panel according to any one of claims 18 to 25, wherein the coating comprises organic components in a non-zero amount up to about 2 wt. % based on the total weight of the inorganic coating.

27. The flame-retardant building panel according to claim 26, wherein the organic component is selected from the groups consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

28. The flame-retardant building panel according to any one of claims 18 to 27, wherein the inorganic coating is present in an amount ranging from about 4.2 g / ft2to about 20 g / ft2.

29. The flame-retardant building panel according to any one of claims 18 to 28, wherein the inorganic coating further comprises aluminum hydroxide.

30. The flame-retardant building panel according to claim 29, wherein the aluminum hydroxide is present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % based on the total weight of the inorganic coating.Attorney Docket No. 22020-00-WO-01-ABP 31. The flame-retardant building panel according to any one of claims 18 to 30, wherein the thickener comprises one or more of hectorite, hydrophobic fumed silica, magnesium aluminosilicate, diatomaceous earth, and hydrophobic modified alkali swellable emulsion, and combinations thereof.

32. The flame-retardant building panel according to any one of claims 18 to 31, further comprising a top coat applied to an upper surface of the inorganic coating.

33. The flame-retardant building panel according to any one of claims 18 to 32, the inorganic coating further comprising magnesium aluminosilicate.

34. A flame-retardant building panel comprising: a body having a first major surface opposite a second major surface; an inorganic coating having an upper surface opposite a lower surface, the inorganic coating comprising: a silicate compound; an alkali siliconate compound; and a top coat; and wherein the inorganic coating is atop the first major surface of the body and the top coat is atop the upper surface of the inorganic coating.

35. The flame-retardant building panel according to claim 33, wherein the body is cellulosic.

36. The flame-retardant building panel according to any one of claims 34 to 35, wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

37. The flame-retardant building panel according to any one of claims 34 to 36, wherein the silicate compound is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the coating.Attorney Docket No. 22020-00-WO-01-ABP 38. The flame-retardant building panel according to any one of claims 34 to 37, wherein the alkali siliconate compound is selected from the group consisting of sodium methyl siliconate, potassium methyl siliconate, and combinations thereof.

39. The flame-retardant building panel according to any one of claims 34 to 38, wherein the alkali siliconate compound is present in an amount ranging from about 9.0 wt. % to about 20.0 wt. % based on the total weight of the inorganic coating.

40. The flame-retardant building panel according to any one of claims 34 to 39, wherein the coating further comprises a dispersant.

41. The flame-retardant building panel according to claim 40, wherein the dispersant is present in an amount ranging from a non-zero value up to about 1.5 wt. % based on the total weight of the inorganic coating.

42. The flame-retardant building panel according to any one of claims 34 to 41, wherein the inorganic coating has a solids content of at least 99 wt. % based on the total weight of the inorganic coating.

43. The flame-retardant building panel according to any one of claims 34 to 42, wherein the coating comprises organic components in a non-zero amount up to about 2 wt. % based on the total weight of the coating.

44. The flame-retardant building panel according to claim 43, wherein the organic component is selected from the groups consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

45. The flame-retardant building panel according to any one of claims 34 to 44, wherein the coating is present in an amount ranging from about 4.2 g / ft2to about 20 g / ft2.Attorney Docket No. 22020-00-WO-01-ABP 46. The flame-retardant building panel according to any one of claims 34 to 45, wherein the coating further comprises aluminum hydroxide.

47. The flame-retardant building panel according to claim 46, wherein the aluminum hydroxide is present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % based on the total weight of the coating.

48. The flame-retardant building panel according to any one of claims 34 to 47, wherein the coating further comprises one or more of hectorite, calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, silica, fumed silica, and combinations thereof.

49. The flame-retardant building panel according to any one of claims 34 to 48, wherein the inorganic coating further comprises magnesium aluminosilicate.

50. The flame-retardant building panel according to claim 49, wherein the magnesium aluminosilicate is present in an amount ranging from about 0.5 wt. % to about 2.0 wt. % based on the total weight of the inorganic coating.

51. A flame-retardant coating composition comprising: a liquid carrier; a solid component comprising: a silicate compound; an alkali siliconate compound; and magnesium aluminosilicate; hectorite; hydrophobic fumed silica; and wherein the coating composition has a pH greater than 8.

52. The flame-retardant coating composition according to claim 51, wherein the pH of the flame- retardant coating ranges from about 9 to about 13.Attorney Docket No. 22020-00-WO-01-ABP 53. The flame-retardant coating composition according to any one of claims 51 to 52, wherein the silicate compound is selected from the group consisting of potassium silicate, tetraethyl orthosilicate, and combinations thereof.

54. The flame-retardant coating composition according to any one of claims 51 to 53, wherein the silicate compound is present in an amount ranging from about 50 wt. % to about 90 wt. % based on the total weight of the solid component.

55. The flame-retardant coating composition according to any one of claims 51 to 54, wherein the alkali siliconate compound is selected from the group consisting of sodium methyl siliconate, potassium methyl siliconate, and combinations thereof.

56. The flame-retardant coating composition according to any one of claims 1 to 5, wherein the alkali siliconate compound is present in an amount ranging from about 9.0 wt. % to about 20 wt.% based on the total weight of the solid component.

57. The flame-retardant coating composition according to any one of claims 51 to 56, wherein the magnesium aluminosilicate is present in an amount ranging from about 0.5 wt. % to about 2.0 wt. % based on the total weight of the solid component.

58. The flame-retardant coating composition according to any one of claims 1 to 7, wherein the solid component of the further comprises a dispersant.

59. The flame-retardant coating composition according to claim 58, wherein the dispersant is present in an amount ranging from a non-zero value up to about 1.5 wt. % based on the total weight of the solid component.

60. The flame-retardant coating composition according to any one of claims 51 to 59, wherein the liquid carrier is present in an amount ranging from about 45 wt. % to about 55 wt. % based on the total weight of the flame-retardant coating composition.Attorney Docket No. 22020-00-WO-01-ABP 61. The flame-retardant coating composition according to any one of claims 51 to 60, wherein the solid component further comprises organic components in a non-zero amount up to about 2 wt. % based on the total weight of the inorganic coating.

62. The flame-retardant coating composition according to claim 61, wherein the organic component is selected from the groups consisting of dispersant, wax blend, wax emulsion, and combinations thereof.

63. The flame-retardant coating composition according to any one of claims 61 to 72, wherein the inorganic coating further comprises hectorite and hydrophilic fumed silica.

64. The flame-retardant coating composition according to any one of claims 61 to 63, wherein the solid component further comprises aluminum hydroxide.

65. The flame-retardant coating composition according to claim 64, wherein the aluminum hydroxide is present in an amount ranging from about 0.5 wt. % to about 12.5 wt. % based on the total weight of the solid component.

66. The flame-retardant coating composition according to any one of claims 51 to 65, wherein the solid component further comprises one or more of calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, silica, and combinations thereof.

67. The flame-retardant coating composition according to any one of claims 51 to 66, wherein the liquid carrier comprises water.

68. A method of forming a flame-retardant building panel comprising a) applying an inorganic coating composition to a major surface of a body; b) drying the inorganic coating composition at an elevated temperature ranging from about 150 °F to about 220 °F to form a flame-retardant coating atop the body; wherein the inorganic coating composition comprises a liquid carrier, a silicate compound, and an alkali siliconate compound; andAttorney Docket No. 22020-00-WO-01-ABP wherein the flame-retardant coating has a solids content of at least 99 wt. % based on the total weight of the flame-retardant coating.

69. The method according to claim 68, wherein the inorganic coating composition has a minimum pH of about 9.

70. The method according to any one of claims 68 to 69, wherein the liquid carrier is present in an amount ranging from about 40 wt. % to about 95 wt. % based on the total weight of the inorganic coating composition.

71. The method according to any one of claims 68 to 70, wherein the liquid carrier comprises water.

72. The method according to any one of claims 68 to 71, wherein the inorganic coating composition is applied to the major surface of the body in an amount ranging from about 100 g / m2to about 400 g / m2.

73. The method according to any one of claims 68 to 72, wherein the flame-retardant coating is present atop the body in an amount ranging from about 4.2 g / ft2to about 20 g / ft2.

74. The method according to any one of claims 68 to 73, wherein the major surface of the body is cellulosic.

75. The method according to any one of claims 68 to 74, wherein the inorganic coating composition comprises up to about 2.5 wt. % of organic components based on the total weight of the inorganic coating composition.

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