Ultra-deep base coating compositions, coated structures, and methods for making the same

Abstract

Disclosed is a coating composition suitable for application to a panel. The coating composition includes a pigment blend. The pigment blend includes calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. The coating composition further includes a binder. A ratio of pigment-to-binder is from about 3:1 to about 6:1. Also disclosed are building panels coated with the coating composition and methods for their formation.

Description

ULTRA-DEEP BASE COATING COMPOSITIONS, COATED STRUCTURES, AND METHODS FOR MAKING THE SAME CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of priority to United States Provisional Patent Application Serial No. 63 / 535,242 filed August 29, 2023, the entirety of which is incorporated herein by reference. FIELD OF THEDISCLOSURE

[0002] The present disclosure relates to coating compositions for coating panels, such as ceiling and wall panels, and more particularly to coating compositions for ultra-deep base paints. BACKGROUND

[0003] Building materials, such as planks and panels of ceiling and wall systems, are commonly coated with coating compositions, such as paints, for aesthetic purposes. Ultra-deep base paints for dark colors typically do not contain titanium dioxide because the presence of titanium dioxide necessitates higher pigment concentrations, which may be detrimental to the performance of the composition, particularly to the acoustical properties. Titanium dioxide, however, advantageously offers desirable hiding properties for aesthetic purposes.

[0004] Accordingly, there is a need for improved coating compositions having sufficient hiding properties while maintaining desired acoustical properties. SUMMARY

[0005] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0006] Applicants have discovered coating compositions useful for application on panels, such as wall or ceiling panels.

[0007] In one example, the disclosed coating composition includes a pigment blend including calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. Thecoating composition further includes a binder in an amount such that a ratio of pigment-to-binder is from about 3:1 to about 6:1.

[0008] In certain examples, the pigment-to-binder ratio is about 5:1. In certain examples, the binder comprises vinyl acrylic polymer. In certain examples, the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition. In certain examples, the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes water present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition. In certain examples, the coating composition includes a hydrophobic polymer emulsion present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes a wetting and dispersing additive comprising an anionic copolymer having an acid value of about 2 mg KOH / g and present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes clay, such as hectorite clay, present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes a defoamer, such as wax and mineral oil, present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition. In certain examples, the coatingcomposition includes one or more biocides present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition. In certain examples, the pigment blend of the coating composition includes precipitated synthetic silicate present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition. In certain examples, the pigment blend of the coating composition includes a calcined extender present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

[0009] Also disclosed are panels.

[0010] In one example, the panel has a first major surface opposite a second major surface and a side surface extending there-between, the panel is coated on at least one surface with a coating composition. The coating composition includes a pigment blend. The pigment blend includes calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. The coating composition further includes a binder in an amount such that a ratio of pigment-to-binder is from about 3:1 to about 6:1.

[0011] In certain examples, the pigment-to-binder ratio is about 5:1. In certain examples, the binder comprises vinyl acrylic polymer present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition. In certain examples, the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition of the panel further includes water present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition. In certain examples, the coating composition of the panel includes a hydrophobic polymer emulsion present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition. In certain examples, the coating composition of the panel includes a wetting and dispersing additive comprising an anionic copolymer having an acid value of about 2 mg KOH / g present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition of the panel includes clay, such as hectorite clay, present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition of the panel includes a defoamer, such as wax and mineral oil, present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition. In certain examples, the coating composition of the panel includes one or more biocides present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition. In certain examples, the pigment blend includes precipitated synthetic silicate present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition. In certain examples, the pigment blend includes a calcined extender present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition. In certain examples, the panel includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the panel is a ceiling or wall panel.

[0012] In another example, the panel includes a substrate having a first major surface opposite a second major surface and a side surface extending there-between, a scrim having a first major scrim surface opposite a second major scrim surface, an adhesive adhering the first major substrate surface of the substrate to the second major scrim surface of the scrim, and a coating composition over the first major scrim surface. The coating composition includes a pigment blend having calcium carbonate, titanium dioxide, calcined diatomaceous earth, and aluminum hydroxide. Thecoating composition further includes a binder in an amount such that a ratio of pigment-to-binder is from about 3:1 to about 6:1.

[0013] In certain examples, the pigment-to-binder ratio is about 5:1. In certain examples, the binder comprises vinyl acrylic polymer present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition. In certain examples, the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes water present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition. In certain examples, the coating composition includes a hydrophobic polymer emulsion present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition. In certain examples, the composition further includes a wetting and dispersing additive comprising an anionic copolymer having an acid value of about 2 mg KOH / g and present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes clay, such as hectorite clay, present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes a defoamer, such as wax and mineral oil, present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes one or more biocides presentin an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition. In certain examples, the pigment blend includes precipitated synthetic silicate present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition. In certain examples, the pigment blend includes a calcined extender present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition. In certain examples, the panel includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the scrim includes laminated non-woven glass fibers in a resin matrix. In certain examples, the adhesive includes a water based polyvinyl acetate emulsion. In certain examples, the panel is a ceiling or wall panel.

[0014] Also disclosed are methods for forming a building panel comprising a coating composition.

[0015] In one example, the method includes mixing calcium carbonate, titanium dioxide, calcined diatomaceous earth, aluminum hydroxide, and a binder in an amount having a pigment-to-binder ratio of about 3:1 to about 6:1 with a solvent to form a mixed composition. The method further includes applying the mixed composition to a surface of a panel and drying the panel to evaporate the solvent to yield a dry coating composition.

[0016] In certain examples, the drying is performed at room temperature, between 20 °C to about 25 °C. In certain examples, the solvent is water present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition. In certain examples, the pigment-to-binder ratio is about 5:1. In certain examples, the binder comprises vinyl acrylic polymer present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition. In certain examples, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition. In certain examples, the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition. In certain examples, the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of thecomposition. In certain examples, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes a hydrophobic polymer emulsion present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition. In certain examples, the composition includes a wetting and dispersing additive comprising an anionic copolymer having an acid value of about 2 mg KOH / g and present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes clay, such as hectorite clay, present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes a defoamer, such as wax and mineral oil, present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition. In certain examples, the coating composition includes one or more biocides present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition. In certain examples, the pigment blend includes precipitated synthetic silicate present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition. In certain examples, the pigment blend includes a calcined extender present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition. In certain examples, the panel is a ceiling or wall panel. In certain examples, the mixed composition is applied to a scrim coupled to the panel.

[0017] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred examples of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.DESCRIPTION OF THE DRAWINGS

[0018] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.

[0019] Figure 1 is top perspective view of a coated building panel according to an example of the present disclosure;

[0020] Figure 2 is a cross-sectional view of the coated building panel according to an example of the present disclosure, the cross-sectional view being along the II line set forth in Figure 1;

[0021] Figure 3 is cross-sectional view of a coated building panel according to an example of the present disclosure;

[0022] Figure 4 is an example of a ceiling system comprising the coated building panel of the present disclosure;

[0023] Figure 5 is a cross-sectional close-up view of the edges of building panels according to certain examples of the present disclosure;

[0024] Figure 6 is a close-up view of a ceiling system comprising the coated building panel according to an example of the present disclosure, the close-up view being the portion identified by oval V in Figure 4;

[0025] Figure 7 is a graph illustrating titanium dioxide content impact on opacity; and

[0026] Figure 8 is a graph illustrating burnish testing results. DETAILED DESCRIPTION

[0027] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0028] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of thosechemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0029] 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.

[0030] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a “wt. %” refers to the amount of that molecule, or molecules, present in the composition based on the total weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition in a dry state. The “dry state” refers to solvent being present in the composition at an amount less than 5.0 wt. %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present “based on the wet weight of the composition” refers to that molecule, or molecules, being present in the composition based on the total weight of the composition which includes at least 5 wt. % of solvent.

[0031] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / - 5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0033] In the description of examples 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 disclosure. 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 (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0034] As used herein, terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and the like 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. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0035] The present disclosure relates to coating compositions, methods for making coating compositions, and panels coated with the disclosed coating compositions. The disclosure utilizes a coating composition designed for ultra-deep base paints, such as dark red and black paints, having a light reflectance value of less than 40 with sufficient hiding properties and tinting ability. In one example, the disclosure yields a black coating composition having a light reflectance value of about 4 to about 7. However, it is understood that any color having a light reflectance value of less than 40 may be achieved by the present disclosure.

[0036] In one aspect, the disclosed coating composition includes a pigment blend and binder such that the pigment-to-binder ratio is about 3:1 to about 6:1, and more preferable about 5:1. The disclosed coating composition further includes titanium dioxide at a concentration of about 1 wt.% to about 2 wt. %, or preferably from about 1.25 wt. % to about 1.75 wt. %, based upon the dry weight of the coating composition. The advantageously yields improved titanium dioxide efficiency at lower concentrations without increasing the whiteness of the paint. The pigment-to- binder ratio is specifically designed to optimize the material and optical properties to yield improved burnish resistance of the coating composition without impacting the hiding power of the coating composition.

[0037] In one or more example, the disclosed coating composition includes a pigment blend. The pigment blend includes a mix of pigments and fillers, such as titanium dioxide extenders, designed to adequately cover panels, such as ceiling panels, as seams between the panels, while maintaining desired material properties, such as acoustical and optical. The disclosed coating composition allows for optimal porosity and airflow to achieve desired acoustical properties.

[0038] In one or more examples, the pigment blend includes calcium carbonate. In one example, the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, based on the dry weight of the composition. In another example, the calcium carbonate is present in an amount from about 25 wt. % to about 35 wt. %, based on the dry weight of the composition. In yet another example, the calcium carbonate is present in an amount from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

[0039] In one or more examples, the pigment blend includes titanium dioxide. The titanium dioxide may be present at any concentration needed to achieve the desired pigment-to-binder ratio as described herein. In one example, the titanium dioxide is present at a concentration from about 0.1 wt. % to about 5 wt. %, based upon the dry weight of the composition. In another example, the titanium dioxide is present at a concentration from about 0.5 wt. % to about 4 wt. %, based upon the dry weight of the composition. In yet another example, the titanium dioxide is present at a concentration or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition. In a preferred example, the titanium dioxide is present at a concentration from about 1 wt. % to about 2 wt. %, based upon the dry weight of the composition.

[0040] In one or more examples, the pigment blend includes calcined diatomaceous earth. The calcined diatomaceous earth may be present at any concentration needed to achieve the desired pigment-to-binder ratio as described herein. In one example, the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, based on the dry weight of the composition. In another example, the calcined diatomaceous earth is present in an amount from about 5 wt. % to about 17.5 wt. %, based on the dry weight of the composition. In yet another example, the calcined diatomaceous earth is present in an amount from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition.

[0041] In one or more examples, the pigment blend includes aluminum hydroxide. The aluminum hydroxide may be present at any concentration needed to achieve the desired pigment-to-binder ratio as described herein. In one example, the aluminum hydroxide is present in an amount fromabout 3 wt. % to about 20 wt. %, based on the dry weight of the composition. In another example, the aluminum hydroxide is present in an amount from about 5 wt. % to about 18 wt. %, based on the dry weight of the composition. In yet another example, the aluminum hydroxide is present in an amount from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

[0042] The coating composition further includes a binder. In one example, the binder comprises vinyl acrylic polymer, such as polyvinyl acrylic. In another example, the binder comprises polyvinyl, acetate. The binder is present at any concentration needed to achieve the desired pigment-to-binder ratio as described herein. In one example, the binder is present in an amount from about 2 wt. % to about 20 wt. %, based on the dry weight of the composition. In another example, the binder is present in an amount from about 2 wt. % to about 18 wt. %, based on the dry weight of the composition. In yet another example, the binder is present in an amount from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

[0043] In certain examples, the vinyl acrylic polymer is anionic and has a Tg of about 37 °C. In certain examples, the vinyl acrylic polymer has a viscosity of about 30 cP, as measured by Brookfield LVT #2 at 60 rpm. In another example, the vinyl acrylic polymer has a pH of about 7.0. In yet another example, the vinyl acrylic polymer has a solids content of about 50%. In certain embodiments, the vinyl acrylic polymer has a specific gravity of about 1.08.

[0044] The amount of pigment blend and binder may be defined by a ratio of pigment-to-binder. In one or more examples, the ratio of pigment-to-binder is from about 3:1 to about 6:1. In another example, the pigment-to-binder ratio is about 4:1 to about 5:1. In a preferred example, the pigment- to-binder ratio is about 5:1.

[0045] The coating composition may further include a solvent. In one example, the solvent is water. In one example, the water is present in an amount from about 10 wt. % to about 20 wt. %, based upon the wet weight of the composition. In another example, the water is present in an amount from about 12 wt. % to about 18 wt. %, based upon the wet weight of the composition. In yet another example, the water is present in an amount from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition.

[0046] In one or more examples, the coating composition further includes a hydrophobic polymer emulsion. In one example, the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, based on the dry weight of the composition. In another example, the hydrophobic polymer emulsion is present in an amount from about 0.5 wt. % to about 5.0 wt. %,based on the dry weight of the composition. In yet another example, the hydrophobic polymer emulsion is present in an amount from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

[0047] The coating composition optionally includes a wetting and dispersing additive. In one example, the wetting and dispersing additive includes an anionic copolymer. The wetting and dispersing additive may have an acid value of about 2 mg KOH / g. In one example, the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, based on the dry weight of the composition. In another example, the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 2 wt. %, based on the dry weight of the composition. In yet another example, the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

[0048] The coating composition optionally includes clay, such as a hectorite clay. In one example, the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, based on the dry weight of the composition. In another example, the clay is present in an amount from about 0.03 wt. % to about 2 wt. %, based on the dry weight of the composition. In yet another example, the clay is present in an amount from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

[0049] The coating composition optionally includes a defoamer. The defoamer may include wax and / or mineral oil. In one example, the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, based on the dry weight of the composition. In another example, the defoamer is present in an amount from about 0.01 wt. % to about 1 wt. %, based on the dry weight of the composition. In yet another example, the defoamer is present in an amount from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition.

[0050] The coating composition optionally includes one or more biocides, such as an antimicrobial or antifungal additive. In one example, the one or more biocides are present in an amount from about 0.01 wt. % to about 1 wt. %, based on the dry weight of the composition. In another example, the one or more biocides are present in an amount from about 0.05 wt. % to about 0.5 wt. %, based on the dry weight of the composition. In yet another example, the one or more biocides are present in an amount from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition.

[0051] The pigment blend of the coating composition optionally includes a precipitated synthetic silicate additive. In one example, the precipitated synthetic silicate is present in an amount from 1wt. % to about 5 wt. %, based on the dry weight of the composition. In another example, the precipitated synthetic silicate is present in an amount from about 1.5 wt. % to about 3.5 wt. %, based on the dry weight of the composition. In yet another example, the precipitated synthetic silicate is present in an amount from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition.

[0052] The pigment blend of the coating composition optionally includes s a calcined extender additive. In one example, the calcined extender is present in an amount from about 1 wt. % to about 6 wt. %, based on the dry weight of the composition. In another example, the calcined extender is present in an amount from about 2 wt. % to about 5 wt. %, based on the dry weight of the composition. In yet another example, the calcined extender is present in an amount from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

[0053] Referring to Figures 1 through 6, also disclosed are panels, such as ceiling or wall panels. In one example, the panels are acoustical panels having appropriate acoustical characteristics for the specified application. Some non-limiting examples of panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinations thereof, or other. Examples of panels have a sufficiently high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating to be characterized as an acoustical substrate in contrast to gypsum-based drywall having substantially lower NRCs (e.g. 0.05) characteristic of sound reflecting, not absorbing materials. NRC is a measure of sound energy absorption of a material. An NRC rating of 0 is a perfect sound reflection material. An NRC rating of 1 is a perfect sound absorption material. CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to / from the plenum above the ceiling. In one or more examples, the disclosed panel 100 with the coating composition 200 yields a NRC rating of about 0.8.

[0054] In certain examples, the disclosed panel may comprise one or more fire retardants. In certain examples, the fire retardant is selected from magnesium oxide, sodium silicate, magnesium sulfate, calcium carbonate, ammonium polyphosphate, or a combination thereof. The one or more fire retardants may be present at various amounts or concentrations. In certain examples, the one or more fire retardants are present in an amount from about 50 wt. % to about 70 wt. %. In certain embodiments, magnesium oxide may be present in an amount from about 10 to about 25 wt. %. In another example, sodium silicate may be present in an amount from about 10 to about 25 wt.%. In yet another example, magnesium sulfate may be present in an amount from about 5 to about 10 wt. %. In a further example, calcium carbonate may be present in an amount from about 5 to about 10 wt. %.

[0055] In some examples, the panels according to the present disclosure may have an NRC of at least 0.50 and / or CAC of at least 230 depending on the desired acoustical characteristics of the ceiling system. In a certain example, the NRC rating may be at least 0.70. The shiplap and tongue- in-groove edge details may be formed by any fabrication process or combination of processes capable of making the details. Non-limiting examples include cutting, routing, milling, casting, molding, etc.

[0056] In some examples, the disclosed panels may be composite structures formed from two or more separately formed layers or sheets of material which are bonded or joined together to form a complete panel.

[0057] Referring to Figures 1 and 5, in certain aspects, the present disclosure includes a coated panel 100 (referred to herein as “building panel”) comprising a first major surface 111 opposite a second major surface 112 and a side surface 113 that extends between the first major surface 111 and the second major surface 112, thereby defining a perimeter of the ceiling panel 100. In certain examples, the side surface 113 may comprise an upper portion 113a and a lower portion 113b, wherein the upper portion 113a is adjacent to the first major surface 111 and the lower portion 113b is adjacent to the second major surface 112. In other examples, as shown in Figure 3, the building panel 100 may include a scrim 130 coupled to one of the first major surface 111 or the second major surface 112 via an adhesive. In one example, the scrim 130 is an unfilled scrim.

[0058] The building panel 100 may have a panel thickness t0 as measured from the first major surface 111 to the second major surface 112. The panel thickness t0 may range from about 12 mm to about 40 mm – including all values and sub-ranges there-between. The building panel 100 may have a length LP ranging from about 30 cm to about 310 cm – including all values and sub-ranges there-the building panel 100 may have a width WP ranging from about 10 cm to about 125 cm – including all values and sub-ranges there-between. The density of the building panel may vary. In certain examples, the density of the building panel is from about 0.3 g / cm3 to about 1.5 g / cm3. In certain examples, the building panel density is from about 0.4 g / cm3 to about 0.9 g / cm3. In further examples, the building panel density is from about 0.5 g / cm3 g / cm3 to about 0.7 g / cm3.

[0059] The building panel 100 comprises a body 120 and a surface coating 200 applied thereto – as discussed further herein. The body 120 comprises an upper surface 121 opposite a lower surface 122 and a body side surface 123 that extends between the upper surface 121 and the lower surface 122, thereby defining a perimeter of the body 120. The body 120 may have a body thickness t1 that extends from the upper surface 121 to the lower surface 122. The body thickness t1 may range from about 12 mm to about 40 mm – including all values and sub-ranges there-between. The body 120 may be porous, thereby allowing airflow through the body 120 between the upper surface 121 and the lower surface 122. The body 120 may be comprised of a binder and fibers. In some examples, the body 120 may further comprise a filler and / or additive.

[0060] Figure 2 shows an example where a coating 200 is present on the upper surface 121 and body side surface 123 of the body 120. In other examples, the coating 200 may be only on the upper surface 121, the lower surface 122, the body side surface 123, or a combination thereof. The coating 200 comprises a first side 211 opposite a second side 212. The coating 200 may have a thickness t2 as measured from the first side 211 to the second side 212. One of skill in the art would recognize that a scrim 130 may be applied between the coating 200 and the body 120 without deviating from the disclosure. Where a coating is present, the total thickness t0 of the building panel 100 includes the thickness of the coating 200.

[0061] Figure 3 illustrates an example where a scrim 130 is present on the upper surface 121 of the body 120 and the coating 200 is present on a first major scrim surface 132. The scrim 130 includes a first major scrim surface 132 opposite a second major scrim surface 134. The coating 200 comprises a first side 211 opposite a second side 212. The coating 200 may have a thickness t2 as measured from the first side 211 to the second side 212. One of skill in the art would recognize that the scrim 130 may be positioned between the coating 200 and the body 120 or over the coating 200 without deviating from the disclosure. Where a coating 200 and scrim 130 are present, the total thickness t0 of the building panel 100 includes the thickness of the coating 200 and the scrim 130.

[0062] In certain examples, the building panel may be embossed. Embossment allows for enhanced visual effects of the building panel. For example, various designs and visual depths may be introduced with embossment. In certain examples, the building panel may be embossed with various patterns including, but not limited to, woodgrain, smooth or rough textures. Standard methods may be used for the embossment.

[0063] The present disclosure may further include a ceiling system. Figure 4 shows an example of a ceiling system 1 comprising one or more of the building panels 100 installed in an interior space, whereby the interior space comprises a plenum space 3 and an active room environment 2. The building panels 100 may be joined together via a joint compound. Any all-purpose, commercially-available joint compound material may be used without departing from the scope of the disclosure. The present disclosure is designed such that the coating 200 may be applied over both the building panels 100 and joint compound connecting the building panels 100 and offer desirable hiding power for both the panels 100, scrim 130 if present over the panels 100, and joint compound.

[0064] The plenum space 3 provides space for mechanical lines within a building (e.g., HVAC, plumbing, etc.). 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.). In the installed state, the building panels 100 may be supported in the interior space by one or more parallel support struts 5. Each of the support struts 5 may comprise an inverted T-bar having a horizontal flange 31 and a vertical web 32. The ceiling system 1 may further comprise a plurality of first struts that are substantially parallel to each other and a plurality of second struts that are substantially perpendicular to the first struts (not pictured). In some examples, the plurality of second struts intersects the plurality of first struts to create an intersecting ceiling support grid 6. The plenum space 3 exists above the ceiling support grid 6 and the active room environment 2 exists below the ceiling support grid 6.

[0065] In the installed state, the first major surface 111 of the building panel 100 may face the active room environment 2 and the second major surface 112 of the building panel 100 may face the plenum space 3. The building panel 100 may be installed according to at least two variations. In a first variation, the building panel 100 is positioned entirely above the horizontal flange 31 of the support struts 5. In the first variation, at least a portion of the first major surface may be concealed from the active room environment 2 by the horizontal flange 31 because the horizontal flange 31 contacts the first major surface 111, thereby supporting it in the ceiling system 1. In a first variation, the entire side surface 113 – including the upper portion 113a and the lower portion 113b – may be concealed from the active room environment 2 by the horizontal flange 311. A second variation will be described further herein.

[0066] Referring now to Figure 5, examples of building panels 300, 400, 500 are illustrated in accordance with other aspects of the present disclosure. The building panels 300, 400, and 500 are similar to building panel 100 except as described herein below. The description of building panel 100 above generally applies to building panels 300, 400, and 500 described below except with regard to the differences specifically noted below. A similar numbering scheme will be used for the building panels 300, 400, and 500 as with building panel 100 except that the 300-, 400-, and 500- series of numbers will be used.

[0067] Referring now to Figure 6, the building panel 500 may be installed according to a second variation, as described herein. The building panel 500 may be positioned such that the upper portion 513a of the side surface 513 is below the horizontal flange 31, thereby extending into the active room environment 2. The lower portion 513b of the side surface 513 is above the horizontal flange 31 extending into the plenum space 3. The first major surface 511 and the upper portion 513a of the side surface 513 of the building panel 500 is exposed to the active room environment 2. The lower portion 513b of the side surface 513 may be concealed from the active room environment 2. The lower portion 513b of the side surface 513 may be adjacent to at least a portion of the vertical web 32 as viewed along a horizontal direction. The lower portion 513b of the side surface 513 as well as the second major surface 512 may be exposed to the plenum space 3.

[0068] In one or more examples, the upper portion 513a and the lower portion 513b may comprise the surface coating 200. In certain examples, the first major surface 511 may comprise the surface coating 200. Therefore, in certain examples, the surface coating 200 may be exposed to the active room environment on the first major surface 511 and the upper portion 513a of the side surface 513 of the building panel 500 in the installed state.

[0069] One of skill in the art would appreciate that the coating composition may also be used in other ceiling systems. Therefore, the examples described above are non-limiting examples.

[0070] In other examples, the coated building panel of the disclosure may be used as a surface covering system. In certain examples, the surface covering system comprises a system of panels, each panel comprising a first building panel having a rectangular shape, a first major surface opposite a second major surface and side surfaces extending there-between, a second building panel having a rectangular shape, a first major surface opposite a second major surface and side surfaces extending there-between, a third building panel having a rectangular shape, a first major surface opposite a second major surface and side surfaces extending there-between, wherein thefirst major surface of the first building panel is in contact with the second major surface of the second building panel, the first major surface of the second building panel is in contact with the second major surface of the third building panel, and wherein the side surfaces of the first building panel and the side surfaces of the third building panel are parallel and the side surfaces of the first building panel and the side surfaces of the second building panel are not parallel. Any one or more of the panels and / or panel surfaces may be covered by the inventive coating composition.

[0071] The inventive coated building panel may be attached to a substrate, thus creating a surface covering system. Without intending to be limited, the building panel may be included in a removable surface covering system using adhesive components as disclosed in U.S. Patent Application No. 2019 / 0270275, filed March 2, 2019. For example, in certain examples, the disclosure is a surface covering system as described herein, further comprising an adhesive tape configured to detachably couple the panels to a substrate, the adhesive tape comprising a substrate- side adhesive component comprising at least one adhesive layer; a panel-side adhesive component comprising at least one adhesive layer; and a release component; wherein the panels are detachably coupled to the substrate by the adhesive tape in a side-by-side arrangement to cover the substrate, the at least one adhesive layer of the substrate-side adhesive component being adhered to the substrate, the at least one adhesive layer of the panel-side adhesive component being adhered to the rear surfaces of the panels, and the release component being positioned between the substrate- side adhesive component and the panel-side adhesive component. In other examples, the surface covering system comprises an adhesive tape configured to detachably couple the panels to a substrate, the adhesive tape comprising a panel-side adhesive component comprising at least one adhesive layer; an optional substrate-side adhesive component comprising at least one adhesive layer; and an optional release component; wherein the panels are detachably coupled to the substrate by the adhesive tape in a side-by-side arrangement to cover the substrate, the at least one adhesive layer of the substrate-side adhesive component being adhered to the substrate, the at least one adhesive layer of the panel-side adhesive component being adhered to the rear surfaces of the panels, and the release component being positioned between the substrate-side adhesive component and the panel-side adhesive component.

[0072] In other examples, the acoustic building panel may be directly attached to a substrate using one or more attaching means. In certain examples, attachment may be accomplished by use of one or more of clips, screw, or adhesive. Various adhesives are known in the art. In a certain non-limiting example, the adhesive is made from synthetic rubber and resin. In certain examples, the synthetic rubber and resin has a viscosity of about 230,000 cps. In certain examples, the synthetic rubber and resin has a flash point of about -17 oC. In another non-limiting example, the adhesive is a water based rubber resin. In another non-limiting example, the adhesive is a two component cross-linking diisocyanate waterborne emulsion. In other examples, the adhesive is an aqueous polyvinyl acetate emulsion. In certain examples, a water based adhesive using emulsion polymer isocyanate may be used. In other examples, a polyurethane based adhesive may be used. In some examples the adhesive may be a pressure sensitive adhesive, a hot melt adhesive, or a combination thereof. In some examples, the adhesive comprises a hot melt adhesive. In some examples, the adhesive comprises a pressure sensitive adhesive. In some examples, the adhesive comprises polyvinyl acetate. In some examples, the adhesive comprises ethylene vinyl-acetate (EVA).

[0073] In certain examples, the adhesive is applied at 3 to 30 g / ft2. In certain examples, the adhesive is applied at 10 to 25 g / ft2. In certain examples, the adhesive is applied at 12 to 20 g / ft2. In certain examples, the adhesive is a two-component cross-linking diisocyanate waterborne emulsion applied at 10 to 25 g / ft2. In certain examples, the adhesive is a two component cross- linking diisocyanate waterborne emulsion applied at 15 to 25 g / ft2. In certain examples, the adhesive is an aqueous polyvinyl acetate emulsion applied at 8 to 25 g / ft2. In certain examples, the adhesive is an aqueous polyvinyl acetate emulsion applied at 8 to 15 g / ft2.

[0074] An important characteristic for building materials is the burning performance. ASTM E84- 20 provides methods to determine the relative burning behavior of the material. In particular, ASTM E84-20 provides methods for determining the Flame Spread Index (FSI) which characterizes how far flames generated on the test material spread. The FSI is measured from 0 (indicating no flames) to 200 (which indicates spreading flames). ASTM E84-20 also provides methods for determining the Smoke Developed Index (SDI) which states how much smoke is generated. SDI is measured on a scale of 0 to 450, which correlates to no smoke generated (value of 0) to thick, heavy smoke (value of 450). Obtained FSI and SDI values are then compiled and applied to a three-tiered class system: Class A, Class B, and Class C, with Class A rated materials producing minimal to no flames or smoke, while Class C materials producing the most flames or smoke. In order to qualify as an E84 Class A fire rating, a flame spread index (FSI) of 25 or less and smoke developed index (SDI) at 450 or less must be exhibited. In certain examples, the building panel has a flame spread index (FSI) of about 0 to about 10, as determined by ASTME84-20. In certain examples, the building panel has a flame spread index (FSI) of about 10 as determined by ASTM E84-20. In certain examples, the building panel has a flame spread index (FSI) of about 0 as determined by ASTM E84-20. In certain examples, the building panel has a smoke developed index (SDI) of about 450, or less, as determined by ASTM E84-20. In certain examples, the building panel has a smoke developed index (SDI) of about 350, or less, as determined by ASTM E84-20.

[0075] Also disclosed is a method for forming a building panel 100 comprising a coating composition 200 as shown and described herein. In one example, the method includes mixing calcium carbonate, titanium dioxide, calcined diatomaceous earth, aluminum hydroxide, and a binder in an amount having a pigment-to-binder ratio of about 3:1 to about 6:1 with a solvent, such as water, to form a mixed composition.

[0076] The method further includes applying the mixed composition to a surface of a panel 100. In one example, the method includes applying the mixed composition to one of a first major surface 111 and a second major surface 112 of the panel 100. In another example, the method includes applying the mixed composition to a scrim 130 coupled to the panel 100.

[0077] The method further includes drying the panel 100 to evaporate the solvent to yield a dry coating composition 200. In one example, the drying is performed at room temperature, i.e. about 20 °C to about 22°C. In another example, the drying is performed at an elevated temperature, such as between 25 °C to about 85 °C. EXAMPLES

[0078] The examples and other implementations described herein are exemplary and not intended to be limiting in describing the full scope of compositions and methods of this disclosure. Equivalent changes, modifications and variations of specific implementations, materials, compositions, and methods may be made within the scope of the present disclosure, with substantially similar results. Unless otherwise indicated, all viscosity values are as measured by Brookfield LVT #2 at 10 rpm and 20oC.

[0079] Experiment 1: Formation of coating composition and testing of opacity and burnish testing. Coating compositions were prepared in approximate amounts as described in Table 1.Table 1: Base coating composition. Solids (%) of Component Component Attribute Wet Weight (%) Individual Dry Weight % % [panels with scrim and joint compound for testing. Color and lightness were tested on the above- mentioned samples, under conditions as outlined in Table 2 below.Table 2: Color and Gloss Data ULTIMA® ULTIMA® Joint CALLA® Filled CALLA® Joint Scrim Area Compound Area Scrim Area Compound Area n’spigment-to-binder ratio and variations of titanium dioxide content. As shown in Figure 8, samples 54A and 57C with the 5:1 and 3:1 pigment-to-binder ratios, respectively, exhibited the lowest Delta 85 gloss and Delta E, showing least color and gloss changes over the coated surfaces. Further, as shown in Figure 7, increasing titanium dioxide yielded increase in amount of colorants needed for achieving desirable opacity of the coatings. A composition having about 1% titanium dioxide was selected for the formulation to provide both good hiding power and tinting ability. Acoustical testing was further conducted and the samples advantageously exhibited an NRC rating of 0.8.

[0082] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent tothose of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.

Claims

CLAIMS What Is Claimed Is:

1. A coating composition comprising: a pigment blend comprising: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder, wherein a ratio of pigment-to-binder is from about 3:1 to about 6:

1.

2. The coating composition of claim 1, wherein the pigment-to-binder ratio is about 5:

1.

3. The coating composition of any one of claims 1 to 2, wherein the binder comprises vinyl acrylic polymer.

4. The coating composition of any one of claims 1 to 3, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

5. The coating composition of any one of claims 1 to 4, wherein the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition.

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

7. The coating composition of any one of claims 1 to 6, wherein the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

8. The coating composition of any one of claims 1 to 7, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

9. The coating composition of any one of claims 1 to 8, further comprising water.

10. The coating composition of claim 9, wherein the water is present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition.

11. The coating composition of any one of claims 1 to 10, further comprising a hydrophobic polymer emulsion.

12. The coating composition of claim 11, wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

13. The coating composition of any one of claims 1 to 12, wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer.

14. The coating composition of claim 13, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH / g.

15. The coating composition of any one of claims 13 or 14, wherein the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt.% to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

16. The coating composition of any one of claims 1 to 15 further comprising clay.

17. The coating composition of claim 16, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

18. The coating composition of any of claims 16 to 17, wherein the clay is a hectorite clay.

19. The coating composition of any one of claims 1 to 18, further comprising a defoamer.

20. The coating composition of claim 19, wherein the defoamer comprises wax and mineral oil.

21. The coating composition of any one of claims 19 or 20, wherein the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition.

22. The coating composition of any one of claims 1 to 21 further comprising one or more biocides.

23. The coating composition of claim 22, wherein the one or more biocides are present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition.

24. The coating composition of any of claims 1 to 23, wherein the pigment blend further comprises precipitated synthetic silicate.

25. The coating composition of claim 24, wherein the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition.

26. The coating composition of any one of claims 1 to 25, wherein the pigment blend further comprises a calcined extender.

27. The coating composition of claim 26, wherein the calcined extender is present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

28. A panel comprising a first major surface opposite a second major surface and a side surface extending there-between, the panel coated on at least one surface with a coating composition comprising: a pigment blend comprising: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder, wherein a ratio of pigment-to-binder is from about 3:1 to about 6:

1.

29. The panel of claim 28, wherein the pigment-to-binder ratio is about 5:

1.

30. The panel of any one of claims 28 or 29, wherein the binder comprises vinyl acrylic polymer.

31. The panel of any one of claims 28 to 30, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

32. The panel of claim any one of claims 28 to 31, wherein the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition.

33. The panel of any one of claims 28 to 32, wherein the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition.

34. The panel of any one of claims 28 to 33, wherein the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

35. The panel of any one of claims 28 to 34, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

36. The panel of any one of claims 28 to 35, wherein the coating composition further comprises water.

37. The panel of claim 36, wherein the water is present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition.

38. The panel of any one of claims 28 to 37, wherein the coating composition further comprises a hydrophobic polymer emulsion.

39. The panel of claim 38, wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

40. The panel of any one of claims any one of claims 28 to 39, wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer.

41. The panel of claim 40, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH / g.

42. The panel of any one of claims 40 or 41, wherein the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

43. The panel of any one of claims any one of claims 28 to 42, wherein the coating composition further comprises clay.

44. The panel of claim 43, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

45. The panel of any of claims 43 to 44, wherein the clay is a hectorite clay.

46. The panel of any one of claims any one of claims 28 to 45, wherein the coating composition further comprises a defoamer.

47. The panel of claim 46, wherein the defoamer comprises wax and mineral oil.

48. The panel of any one of claims 46 or 47, wherein the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition.

49. The panel of any one of claims 28 to 48, wherein the coating composition further comprises one or more biocides.

50. The panel of claim 49, wherein the one or more biocides are present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition.

51. The panel of any of claims 28 to 50, wherein the pigment blend further comprises precipitated synthetic silicate.

52. The panel of claim 51, wherein the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition.

53. The panel of any one of claims 28 to 52, wherein the pigment blend further comprises a calcined extender.

54. The panel of claim 53, wherein the calcined extender is present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

55. The panel of any one of claims 28 to 54, wherein the panel comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

56. The panel of any one of claims 28 to 55, wherein the panel is a ceiling or wall panel.

57. A panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending there-between; a scrim having a first major scrim surface opposite a second major scrim surface; an adhesive adhering the first major substrate surface of the substrate to the second major scrim surface of the scrim; anda coating composition over the first major scrim surface, the coating composition comprising: a pigment blend comprising: calcium carbonate; titanium dioxide; calcined diatomaceous earth; and aluminum hydroxide; and a binder, wherein a ratio of pigment-to-binder is from about 3:1 to about 6:

1.

58. The panel of claim 57, wherein the pigment-to-binder ratio is about 5:

1.

59. The panel of any one of claims 57 or 58, wherein the binder comprises vinyl acrylic polymer.

60. The panel of any one of claims 57 to 59, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

61. The panel of any one of claims 57 to 60, wherein the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition.

62. The panel of any one of claims 57 to 61, wherein the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition.

63. The panel of any one of claims 57 to 62, wherein the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

64. The panel of any one of claims 57 to 63, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

65. The panel of any one of claims 57 to 64, wherein the coating composition further comprises water.

66. The panel of claim 65, wherein the water is present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition.

67. The panel of any one of claims 57 to 66, wherein the coating composition further comprises a hydrophobic polymer emulsion.

68. The panel of claim 67, wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

69. The panel of any one of claims 57 to 68, wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer.

70. The panel of claim 69, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH / g.

71. The panel of any one of claims 69 or 70, wherein the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

72. The panel of any one of claims 57 to 71, wherein the coating composition further comprises clay.

73. The panel of claim 72, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

74. The panel of any of claims 72 or 73, wherein the clay is a hectorite clay.

75. The panel of any one of claims 57 to 74, wherein the coating composition further comprises a defoamer.

76. The panel of claim 75, wherein the defoamer comprises wax and mineral oil.

77. The panel of any one of claims 75 or 76, wherein the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition.

78. The panel of any one of claims 57 to 77, wherein the coating composition further comprises one or more biocides.

79. The panel of claim 78, wherein the one or more biocides are present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition.

80. The panel of any of claims 57 to 79, wherein the pigment blend further comprises precipitated synthetic silicate.

81. The panel of claim 80, wherein the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition.

82. The panel of any one of claims 57 to 81, wherein the pigment blend further comprises a calcined extender.

83. The panel of claim 82, wherein the calcined extender is present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

84. The panel of any one of claims 57 to 88, wherein the panel comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

85. The panel of any one of claims 57 to 84, wherein the scrim comprises laminated non-woven glass fibers in a resin matrix.

86. The panel of any one of claims 57 to 85, wherein the adhesive comprises polyvinyl acetate emulsion.

87. The panel of any one of claims 57 to 86, wherein the panel is a ceiling or wall panel.

88. A method for forming a building panel comprising a coating composition, the method comprising: mixing calcium carbonate, titanium dioxide, calcined diatomaceous earth, aluminum hydroxide, and a binder in an amount having a pigment-to-binder ratio of about 3:1 to about 6:1 with a solvent to form a mixed composition; applying the mixed composition to a surface of a panel; and drying the panel to evaporate the solvent to yield a dry coating composition.

89. The method of claim 88, wherein the drying temperature is between 20 °C to about 25 °C.

90. The method of any one of claims 88 or 89, wherein the solvent is water.

91. The method of claim 90, wherein the water is present in an amount from about 10 wt. % to about 20 wt. %, from about 12 wt. % to about 18 wt. %, or from about 13 wt. % to about 15 wt. %, based upon the wet weight of the composition.

92. The method of any one of claims 88 to 91, wherein the pigment-to-binder ratio is about 5:

1.

93. The method of any one of claims 88 to 92, wherein the binder comprises vinyl acrylic polymer.

94. The method of any one of claims 88 to 93, wherein the binder is present in an amount from about 2 wt. % to about 20 wt. %, from about 2 wt. % to about 18 wt. %, or from about 3 wt. % to about 16 wt. %, based on the dry weight of the composition.

95. The method of any one of claims 88 to 94, wherein the titanium dioxide is present at a concentration of about 0.1 wt. % to about 5 wt. %, from about 0.5 wt. % to about 4 wt. %, or from about 1 wt. % to about 3 wt. %, based upon the dry weight of the composition.

96. The method of any one of claims 88 to 95, wherein the calcined diatomaceous earth is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 17.5 wt. %, or from about 7.5 wt. % to about 15 wt. %, based on the dry weight of the composition.

97. The method of any one of claims 88 to 96, wherein the aluminum hydroxide is present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt. % to about 18 wt. %, or from about 10 wt. % to about 15 wt. %, based on the dry weight of the composition.

98. The method of any one of claims 88 to 97, wherein the calcium carbonate is present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 35 wt. %, or from about 27.0 wt. % to about 32.5 wt. %, based on the dry weight of the composition.

99. The method of any one of claims 88 to 98, wherein the coating composition further comprises a hydrophobic polymer emulsion.

100. The method of claim 99, wherein the hydrophobic polymer emulsion is present in an amount from about 0.1 wt. % to about 10 wt. %, from about 0.5 wt. % to about 5.0 wt. %, or from about 0.75 wt. % to about 3 wt. %, based on the dry weight of the composition.

101. The method of any one of claims 88 to 100, wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer.

102. The method of claim 101, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH / g.

103. The method of any one of claims 101 or 102, wherein the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

104. The method of any one of claims 88 to 103, wherein the coating composition further comprises clay.

105. The method of claim 104, wherein the clay is present in an amount from about 0.01 wt. % to about 5 wt. %, from about 0.03 wt. % to about 2 wt. %, or from about 0.03 wt. % to about 0.5 wt. %, based on the dry weight of the composition.

106. The method of any of claims 104 or 105, wherein the clay is a hectorite clay.

107. The method of any one of claims 88 to 106, wherein the coating composition further comprises a defoamer.

108. The method of claim 103, wherein the defoamer comprises wax and mineral oil.

109. The method of any one of claims 107 or 108, wherein the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt. % to about 1 wt. %, or from about 0.01 wt. % to about 0.1 wt. %, based on the dry weight of the composition.

110. The method of any one of claims any one of claims 88 to 109, wherein the coating composition further comprises one or more biocides.

111. The method of claim 110, wherein the one or more biocides are present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.5 wt. %, or from about 0.05 wt. % to about 0.4 wt. %, based on the dry weight of the composition.

112. The method of any of claims any one of claims 89 to 111, wherein the pigment blend further comprises precipitated synthetic silicate.

113. The method of claim 112, wherein the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt. %, from about 1.5 wt. % to about 3.5 wt. %, or from about 2 wt. % to about 3 wt. %%, based on the dry weight of the composition.

114. The method of any one of claims any one of claims 88 to 113, wherein the pigment blend further comprises a calcined extender.

115. The method of claim 114, wherein the calcined extender is present in an amount from about 1 wt. % to about 6 wt. %, from about 2 wt. % to about 5 wt. %, or from about 3 wt. % to about 4 wt. %%, based on the dry weight of the composition.

116. The method of any one of claims 88 to 115, wherein the panel is a ceiling or wall panel.

117. The method of any one of claims 88 to 116, wherein the mixed composition is applied to a scrim coupled to the panel.

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