Durable coatings for acoustic structures and methods for making the same

Abstract

Disclosed is an acoustic panel including a substrate having a first major surface opposite a second major surface and a side surface extending there-between, and a coating over the face and / or side surfaces including a pigment and crosslinking binder. Also disclosed are methods for manufacturing acoustic panels with high strength and durability.

Description

24006-00-WG-01-ABPDURABLE COATINGS FOR ACOUSTIC STRUCTURES AND METHODS FOR MAKING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application that claims the benefit of United States Provisional Patent Application No. 63 / 571,964, filed on March 29, 2024, the disclosure of which is incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to acoustic structures, such as ceiling and wall panels, and more particularly to durable coatings for acoustic structures having high impact resistance and mechanical strength.BACKGROUND

[0003] Building materials, such as planks and panels for ceiling and wall systems, are commonly coated with coating compositions, such as paints, for aesthetic purposes. Building materials and coating compositions may be designed balance interests with respect to aesthetics, material cost, structural integrity, acoustics, and environmental impact.

[0004] Accordingly, those skilled in the art continue research and development in the field of durable coating compositions and high-performing materials for building panels.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 acoustic panels, such as wall or ceiling panels.

[0007] An acoustic panel includes a substrate having a first major surface opposite a second major surface and a side surface extending there-b etween, and coating composition over the side surface.The coating composition includes a crosslinking binder and a pigment. In one example, the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0008] In one example, a ratio of pigment-to-binder ranges from about 0.5: 1 to about 20: 1. In one example, the pigment-to-binder ratio ranges from about 0.5: 1 to about 5: 1. In one example, the binder includes vinyl acetate polymer. In one example, the binder includes a crosslinker present in an amount ranging from about 0.5 wt. % to about 30 wt. %, based on the dry weight of the coating composition. In one example, the binder crosslinker is present in an amount from about 0.5 wt. % to about 20 wt. %, from about 2 wt. % to about 15 wt. %, or from about 3 wt. % to about 10 wt. %, based on the dry weight of the coating composition. In one example, the binder includes a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

[0009] In one example, the pigment includes titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition. In one example, the pigment includes calcined diatomaceous earth 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 coating composition. In one example, the pigment includes aluminum hydroxide 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 coating composition. In one example, the pigment includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.

[0010] In one example, coating composition further includes water. In one example, the water is present in an amount from about 20 wt. % to about 50 wt. %, from about 25 wt. % to about 45 wt. %, or from about 30 wt. % to about 40 wt. %, based upon the wet weight of the coating composition. In one example, the coating composition further includes a hydrophobic polymer emulsion. In one example, the hydrophobic polymer emulsion is present in an amount from about 10 wt. % to about 60 wt. %, from about 20 wt. % to about 50 wt. %, or from about 30 wt. % to about 40 wt. %, based on the dry weight of the coating composition. In one example, the coating composition further includes a wetting and dispersing additive comprising an anionic copolymer. In one example, the wetting and dispersing additive has an acid value of about 2 mg KOH / g. Inone example, 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 coating composition.

[0011] In one example, the coating composition further includes clay. In one example, 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 coating composition. In one example, the clay is a hectorite clay. In one example, the coating composition further includes a defoamer. In one example, the defoamer includes wax and mineral oil. In one example, 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 coating composition. In one example, the coating composition further includes biocide. In one example, the biocide is present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition. In one example, the pigment further includes precipitated synthetic silicate. In one example, 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 coating composition. In one example, the pigment further includes a calcined extender. In one example, the calcined extender is present in an amount from about 1 wt. % to about 25 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 coating composition. In one example, the acoustic panel is a ceiling or wall panel.

[0012] Also disclosed is a method for forming an acoustic building panel.

[0013] In one example, the method includes providing a substrate having a first major surface opposite a second major surface and a side surface extending there-b etween, applying a coating composition including a crosslinking binder and pigment over the side surface, and curing the substrate to yield the acoustic building panel.

[0014] In one example, the applying includes spraying the coating composition at a predetermined application rate over the side surface. In one example, curing includes drying the substrate at a temperature ranging from about 275 °F to about 480 °F.

[0015] In one example, the crosslinking binder includes a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

[0016] 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

[0017] 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.

[0018] Figure 1 is top perspective view of a coated building panel according to an example of the present disclosure;

[0019] Figure 2 is a cross-sectional view of the coated building panel according to an example of the present disclosure;

[0020] Figure 3 is cross-sectional view of a coated building panel according to an example of the present disclosure;

[0021] Figure 4 is an example of a ceiling system comprising the coated building panel of the present disclosure; and

[0022] Figure 5 is a building system comprising one or more of the building panels of Figures 1 to 3.DETAILED DESCRIPTION

[0023] 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 according to any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0024] 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 according to any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical 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”.

[0025] 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.

[0026] 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 coating composition based on the total weight of the coating composition. Unless otherwise specified, reference to a molecule, or to molecules, being present “based on the dry weight of the coating composition” refers to that molecule, or molecules, being present in the coating composition based on the total weight of the coating composition in a dry state. The “dry state” refers to solvent being present in the coating 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 coating 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 coating composition” refers to that molecule, or molecules, being present in the coating composition based on the total weight of the coating composition which includes at least 5 wt. % of solvent.

[0027] 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 coating composition.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] The present disclosure relates acoustic structures, such as ceiling and wall panels, having high impact resistance, high strength, and high sag resistance. The disclosed acoustic panels 100 may exhibit improved impact resistance due to the inclusion of crosslinking adhesives and binders and disclosed herein.

[0032] Referring to Figures 1 through 5, disclosed are acoustic panels, such as ceiling or wall panels. In one example, the acoustic 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 energyabsorption 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 acoustic panel 100 yields a NRC rating of about 0.8.

[0033] 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 acoustic panel 100 has a flame spread index (FSI) of about 0 to about 10, as determined by ASTM E84-20. 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 acoustic panel 100 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 acoustic panel 100 has a smoke developed index (SDI) of about 350, or less, as determined by ASTM E84-20.

[0034] Referring to FIG. 4, the present disclosure may further include a ceiling system. FIG. 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 acoustic 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 andoffer desirable hiding power for both the acoustic panels 100, scrim 130 if present over the acoustic panels 100, and joint compound.

[0035] 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.

[0036] In the installed state, the first major surface 111 of the acoustic panel 100 may face the active room environment 2 and the second major surface 112 of the acoustic panel 100 may face the plenum space 3. The acoustic panel 100 may be installed according to at least two variations. In a first variation, the acoustic 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.

[0037] Referring to FIG. 1, in certain aspects, the present disclosure includes an acoustic panel 100 (sometimes 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 acoustic 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.

[0038] The acoustic panel 100 may have an acoustic panel thickness to as measured from the first major surface 111 to the second major surface 112. The acoustic panel thickness to may rangefrom about 5 mm to about 40 mm - including all values and sub-ranges there-between. The acoustic panel 100 may have a length Lp ranging from about 30 cm to about 310 cm - including all values and sub-ranges there-the acoustic 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 / cm3to about 1.5 g / cm3. In certain examples, the building panel density is from about 0.4 g / cm3to about 0.9 g / cm3. In further examples, the building panel density is from about 0.5 g / cm3to about 0.7 g / cm3.

[0039] The acoustic panel 100 comprises a substrate 120 having a first major surface 121 opposite a second major surface 122 and a substrate side surface 123 that extends between the first major surface 121 and the second major surface 122, thereby defining a perimeter of the substrate 120. The substrate 120 may have a body thickness ti that extends from the first major surface 121 to the second major surface 122. The body thickness ti may range from about 5 mm to about 40 mm - including all values and sub-ranges there-between.

[0040] The substrate 120 may be porous, thereby allowing airflow through the substrate 120 between the first major surface 121 and the second major surface 122. The substrate 120 may be comprised of a binder and fibers. In some examples, the substrate 120 may further comprise a filler and / or additive. In one or more examples, the substrate 100 substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In certain examples, the disclosed substrate 120 may include 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.

[0041] Referring to FIG. 2, in one or more examples, the acoustic panel 100 further includes a coating composition 200 the side surface 113 of the acoustic panel 100. The coating composition 200 includes a pigment and a crosslinking binder. The coating composition 200 defines an edge coating 220 having an inside surface 222 and an outside surface 221.

[0042] In one or more examples, the coating composition 200 has a ratio of pigment-to-binder that ranges from about 0.5 : 1 to about 20: 1 In another example, the pigment-to-binder ratio ranges from about 1 : 1 to about 5: 1.

[0043] In one example, the crosslinking binder includes vinyl acrylic polymer. In another example, the crosslinking binder includes a crosslinker present in an amount ranging from about 0.5 wt. % to about 30 wt. %, based on the dry weight of the coating composition. In one example, the crosslinking binder is present in an amount from about 10 wt. % to about 60 wt. %, from about 20 wt. % to about 50 wt. %, or from about 30 wt. % to about 45 wt. %, based on the dry weight of the coating composition. In a further example, the crosslinking binder includes a blend of at least two binders, wherein at least one binder is non-crosslinkable and the other binder is crosslinking.

[0044] The pigment may include a single pigment of a blend of two or more pigments. In one example, the pigment includes titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.

[0045] In one example, the pigment includes calcined diatomaceous earth 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 coating composition.

[0046] In one example, the pigment includes aluminum hydroxide 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 coating composition.

[0047] In one example, the pigment includes calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.

[0048] In one example, coating composition further includes water. The water may be present in an amount from about 4 wt. % to about 60 wt. %, from about 10 wt. % to about 50 wt. %, or from about 20 wt. % to about 40 wt. %, based upon the wet weight of the coating composition.

[0049] In one example, the coating composition further includes a hydrophobic polymer emulsion. The hydrophobic polymer emulsion may be 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 coating composition.

[0050] In one example, the coating composition further includes a wetting and dispersing additive comprising 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 amountfrom 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 coating composition.

[0051] In one example, the coating composition further includes clay. The clay may be 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 coating composition. In one example, the clay is a hectorite clay.

[0052] In one example, the coating composition further includes a defoamer. The defoamer may include wax and mineral oil. In one example, 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 coating composition.

[0053] In one example, the coating composition further includes biocide. The biocide may be present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.

[0054] In one example, the pigment further includes precipitated synthetic silicate. The precipitated synthetic silicate may be 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 coating composition.

[0055] In one example, the pigment further includes a calcined extender. The calcined extender may be present in an amount from about 1 wt. % to about 25 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 coating composition.

[0056] Still referring to FIG. 2, the acoustic panel 100 may further include a top surface coating 210 having an inside surface 212 and an outside surface 211. The top surface coating 210 may have a composition that is the same as the edge coating 220 or may be different from the edge coating 220.

[0057] Referring to FIG. 3, the acoustic panel 100 may include a scrim 130 having a first major scrim surface 132 opposite a second major scrim surface 134. The scrim 130 may be present on the first major substrate surface 121. The scrim 130 may be adhered to the substrate 120 via an adhesive adhering the first major substrate surface 121 to the second major scrim surface 134. In one example, the scrim 130 includes laminated non-woven glass fibers in a resin matrix.

[0058] In one or more examples, the adhesive includes polyvinyl acetate emulsion. In another example, the adhesive includes a blend of two or more adhesives. The adhesive may be crosslinking. In a further example, the adhesive includes a blend of two or more adhesives. In yet another example, the adhesive includes a blend of two or more adhesives wherein at least one of the adhesives is non-crosslinkable and wherein at least one of the adhesives is crosslinking. In yet another example, the adhesive includes a crosslinker. The adhesive may be present in an amount ranging from about 5 g / ft2to about 40 g / ft2.

[0059] Referring to FIG. 5, in one or more examples, the present disclosure may be implemented in a building system 1. In one example, the present disclosure includes a building system 1 comprising one or more of the acoustic building panels 100 or plurality of acoustic building panels 202 installed in an interior space 8. FIG. 5 shows the acoustic panel 100 installed, however, the following discussion applies to any configuration disclosed herein.

[0060] The interior space 8 may comprise a floor surface 4, equivalent to ground level as disclosed herein, that is opposite a ceiling surface 5. The interior space 8 may further comprise a cavity space 3 and an active room environment 2. The cavity space 3 may provide a free volume for joists and / or wall stud 9 to be located within the acoustic building system 1. The active room environment 2 provides room for the acoustic building occupants during normal intended use of the acoustic building (e.g., in an office building, the active space would be occupied by offices containing computers, lamps, etc.). The floor surface 4 provides for building occupants to walk on within the room environment 2. The floor surface 4 may extend into the cavity space 3. The floor surface 4 may be formed a building material (e.g., wood flooring, concrete flooring, metal grate, etc.).

[0061] In the installed state, the acoustic building panels 100, plurality of acoustic building panels 100 may be supported in the interior space 8 by one or more of the wall studs 9 (for acoustic building panels 100 that function as wall panels) and / or one or more of the ceiling joists (for acoustic building panels 100 that function as ceiling panels - not pictured). In the installed state, the plurality of acoustic building panels 100 supported by the wall studs 9 may form a wall surface 50. In the installed state, the plurality of building panels 100 supported by the ceiling joists may form a ceiling surface 5.

[0062] The plurality of wall studs 9 may be arranged substantially parallel to each other. The plurality of wall studs 9 may be offset from each other by a distance DWS of about 16 inches - asmeasured on center from each adjacent wall stud 9. The distance DWS between wall studs 9 may provide for an open cavity volume 11. The open cavity volume 11 may be an unoccupied space within the acoustic building system 1. In other embodiments, insulation may be installed into the open cavity volume 11 - non-limiting examples of insulation include sound insulation, thermal insulation, and combinations thereto.

[0063] The wall studs 9 may be an elongated body having a substantially vertical orientation - extending in a direction that spans between the floor surface 4 and the ceiling surface 5. Depending on the room layout design, the wall studs 9 may be oriented orthogonal to the floor surface 4 - i.e., resulting in a wall surface 50 that is completely vertical (also referred to as a “vertical wall surface” 50). In other embodiments, the wall studs 9 may be oriented at an angle between about 46° to about 89° relative to the floor surface 4 - i.e., resulting in a wall surface 50 that is slanted (also referred to as a “slanted wall surface” 50).

[0064] Depending on the room layout design, the ceiling surface 5 may be substantially parallel to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is completely horizontal (also referred to as a “horizontal ceiling surface” 5). In other embodiments, the ceiling surface 5 may be oriented at an angle between about 1° to about 44° relative to the floor surface 4 - i.e., resulting in a ceiling surface 5 that is slanted (also referred to as a “slanted ceiling surface” 5).

[0065] The cavity space 3 may exist behind each one of the plurality of acoustic building panels 202. The active room environment 2 may exists in front of each one of the plurality of acoustic building panels 202. The first exposed major surface 116 of each acoustic panel 100 may face the active room environment 2. The second exposed major surface 118 of each acoustic panel 100 may face the cavity space 3. As discussed further herein, the acoustic building panels 100 of the present invention have airflow properties required for the acoustic building panels 100 to functional as acoustical building panels - as discussed further herein.

[0066] In a non-limiting embodiment, the acoustic building panels 100 may be supported by the one or more of the wall studs 9 using a mechanical fastener (e.g., screw), adhesive, or combinations thereto. In a non-limiting embodiment, the acoustic building panels 100 may be support by the one or more ceiling joists using a mechanical fastener (e.g., screw), adhesive, or combinations thereof.

[0067] Each of the acoustic building panels 100 may be positioned within building system 1 such that at least one of the side exposed surfaces 113 is located adjacent to the floor surface 4. Specifically, the first side surface 113a (or second side surface 113b) may be located adjacent tothe floor surface 4 - whereby in such arrangement, the wall acoustic panel 100 is vertically oriented in a sideways manner (not pictured). The wall acoustic panel 100 vertically oriented in the sideways manner may comprise the third side surface 113c and the fourth side surface 113d being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the third side surface 113c and / or fourth side surface 113d may overlap with a single wall stud 9. The wall acoustic panel 100 vertically oriented in the sideways manner may comprise the first side surface 113a and the second side surface 113b being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a plurality of wall studs 9.

[0068] In other embodiments, each of the acoustic building panels 100 may be positioned within building system 1 such that at least one of the side surfaces 113 is located adjacent to the floor surface 4 such that the third side surface 113c (or fourth side surface 113d) may be located adjacent to the floor surface 4 - whereby in such arrangement, the wall acoustic panel 100 is vertically oriented in an upstanding manner. The wall acoustic panel 100 vertically oriented in the upstanding manner may comprise the first side surface 113a and the second side surface 113b being substantially parallel to the elongated body of the wall studs 9 - whereby each one of the first side surface 113a and / or second side surface 113b may overlap with a single wall stud 9. The wall panel 100 vertically oriented in the upstanding manner may comprise the third side surface 113c and the fourth side surface 113d being substantially orthogonal to the elongated body of the wall studs 9 - whereby each one of the third side surface 1 13c and / or fourth side surface 1 13d may overlap with a plurality of wall studs 9.

[0069] In the installed state, the acoustic panel 100 may be secured to one or more of the wall studs 9 such that the acoustic panel 100 is located from the floor surface 4 by an acoustic panelfloor distance DPF. The acoustic panel-floor distance DPF may be determined by the vertical distance spanning between the floor surface 4 and the most-proximate point on the acoustic panel 100 from the floor surface 4. The acoustic panel-floor distance DPF may range from zero to about 7 feet - including all distances and sub-ranges there-b etween. The acoustic panel-floor distance DPF may range from zero to about 6 feet - including all distances and sub-ranges there-between. When the acoustic panel -floor distance DPF is zero, the acoustic panel 100 may be in direct contact with the floor surface 4. In some embodiments, the acoustic panel-floor distance DPF is less than about 6 feet.

[0070] In another aspect, FIG. 5 demonstrates that a first acoustic panel 100a and a second acoustic panel 100b may be positioned adjacent to each other, whereby an acoustic panel seam 215' is located where the first side surface 113a of the first acoustic panel 100a is located adjacent to the second side surface 113b of the second acoustic panel 100b.

[0071] In other embodiments, the acoustic panel 100 may also be installed such that it forms a ceiling surface (not pictured) and / or be position above the acoustic panel-floor distance DPF.

[0072] Furthermore, the disclosed plurality of acoustic building panelslOO includes a first acoustic building panel positioned between ground level and up to 7ft above ground level. The plurality of acoustic building panels 202 further includes a second acoustic building panel positioned adjacent the first acoustic building panel and more than 7ft above ground level (not shown).

[0073] Also disclosed is a method for forming an acoustic building panel 100 as disclosed herein.

[0074] In one example, the method includes providing a substrate 120 having a first major surface 121 opposite a second major surface 122 and a substrate side surface 123 extending there-between.

[0075] In one example, the method includes applying a coating composition 200 to the substrate side surface 123. The coating composition 200 includes a pigment and a crosslinking binder. In one example, the coating composition 200 is sprayed onto the side surface 123.

[0076] In one example, the crosslinking binder includes a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

[0077] In one or more examples, the method further includes applying an adhesive to the first major surface 121 of the substrate 120. The adhesive may include polyvinyl acetate and may be crosslinking. In one example, the applying includes spraying the adhesive at a predetermined application rate. In one example, the adhesive includes a blend of two or more adhesives, wherein at least one of the two or more adhesives is a crosslinking adhesive, and wherein at least one of the two or more adhesives is not crosslinking.

[0078] In one or more examples, the method further includes positioning a scrim 130 over the first major surface 121 of the substrate 120 and laminating the scrim 130 with the first major surface 121 of the substrate 120. In one example, the laminating includes applying pressure with a roller.

[0079] In one or more examples, the method includes curing the substrate to yield the acoustic building panel 100. In one example, curing includes drying the substrate at a temperature ranging from about 275 °F to about 480 °F.

[0080] The disclosure may be further characterized by the following Exemplary Claims.

[0081] Exemplary Claim 1 : An acoustic panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending there-between; and a coating composition over the side surface of the substrate, the coating composition comprising: a pigment; and a crosslinking binder.

[0082] Exemplary Claim 2: The acoustic panel according to Exemplary Claim 1, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

[0083] Exemplary Claim 3 : The acoustic panel according to Exemplary Claim 1 or 2, wherein a ratio of pigment-to-binder ranges from about 0.2: 1 to about 20: 1.

[0084] Exemplary Claim 4: The acoustic panel according to any one of Exemplary Claims 1 to 3, wherein the binder comprises vinyl acetate polymer.

[0085] Exemplary Claim 5: The acoustic panel according to any one of Exemplary Claims 1 to 4, wherein the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.

[0086] Exemplary Claim 6: The acoustic panel according to any one of Exemplary Claims 1 to 5, wherein the binder comprises a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

[0087] Exemplary Claim 7: The acoustic panel according to any one of Exemplary Claims 1 to 6, wherein the binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %, or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.

[0088] Exemplary Claim 8: The acoustic panel according to any one of Exemplary Claims 1 to 7, wherein the pigment comprises titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.

[0089] Exemplary Claim 9: The acoustic panel according to any one of Exemplary Claims 1 to 8, wherein the pigment comprises calcined diatomaceous earth 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 coating composition.

[0090] Exemplary Claim 10: The acoustic panel according to any one of Exemplary Claims 1 to9, wherein the pigment comprises aluminum hydroxide 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 coating composition.

[0091] Exemplary Claim 11 : The acoustic panel according to any one of Exemplary Claims 1 to10, wherein the pigment comprises calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.

[0092] Exemplary Claim 12: The acoustic panel according to any one of Exemplary Claims 1 to11, wherein the coating composition further comprises water.

[0093] Exemplary Claim 13: The acoustic panel according to Exemplary Claim 12, wherein the water is present in an amount from about 20 wt. % to about 60 wt. %, from about 30 wt. % to about 50 wt. %, or from about 40 wt. % to about 60 wt. %, based upon the wet weight of the coating composition.

[0094] Exemplary Claim 14: The acoustic panel according to any one of Exemplary Claims 1 to 13, wherein the coating composition further comprises a hydrophobic polymer emulsion.

[0095] Exemplary Claim 15: The acoustic panel of Exemplary Claim 14, 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 coating composition.

[0096] Exemplary Claim 16: The acoustic panel according to any one of Exemplary Claims 1 to 15, wherein the coating composition further comprises a wetting and dispersing additive comprising an anionic copolymer.

[0097] Exemplary Claim 17: The acoustic panel of Exemplary Claim 16, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH / g.

[0098] Exemplary Claim 18: The acoustic panel according to any one of Exemplary Claims 1 to17, 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 coating composition.

[0099] Exemplary Claim 19: The acoustic panel according to any one of Exemplary Claims 1 to18, wherein the coating composition further comprises clay.

[0100] Exemplary Claim 20: The acoustic panel of Exemplary Claim 19, 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 coating composition.

[0101] Exemplary Claim 21 : The acoustic panel according to any of Exemplary Claims 19 or 20, wherein the clay is a hectorite clay.

[0102] Exemplary Claim 22: The acoustic panel according to any one of Exemplary Claims 1 to 21, wherein the coating composition further comprises a defoamer.

[0103] Exemplary Claim 23: The acoustic panel of Exemplary Claim 22, wherein the defoamer comprises wax and mineral oil.

[0104] Exemplary Claim 24: The acoustic panel according to any one of Exemplary Claims 22 or23, 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 coating composition.

[0105] Exemplary Claim 25: The acoustic panel according to any one of Exemplary Claims 1 to24, wherein the coating composition further comprises biocide.

[0106] Exemplary Claim 26: The acoustic panel according to Exemplary Claim 25, wherein the biocide is present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.

[0107] Exemplary Claim 27: The acoustic panel according to any of Exemplary Claims 1 to 26, wherein the pigment further comprises precipitated synthetic silicate.

[0108] Exemplary Claim 28: The acoustic panel of Exemplary Claim 27, 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 coating composition.

[0109] Exemplary Claim 29: The acoustic panel according to any one of Exemplary Claims 1 to 28, wherein the pigment further comprises a calcined extender.

[0110] Exemplary Claim 30: The acoustic panel of Exemplary Claim 29, wherein the calcined extender is present in an amount from about 1 wt. % to about 25 wt. %, from about 2 wt. % toabout 5 wt. %, or from about 3 wt. % to about 4 wt. %, based on the dry weight of the coating composition.

[0111] Exemplary Claim 31 : The acoustic panel according to any one of Exemplary Claims 1 to 30, wherein the acoustic panel is a ceiling or wall panel.

[0112] Exemplary Claim 32: A method for forming an acoustic building panel, the method comprising: providing a substrate having a first major surface opposite a second major surface and a side surface extending there-between; applying a coating composition over the side surface, the coating composition comprising a crosslinking binder and a pigment; and curing the substrate to yield the acoustic building panel.

[0113] Exemplary Claim 33 : The method according to Exemplary Claim 32, wherein the applying comprises spraying the coating composition at a predetermined application rate.

[0114] Exemplary Claim 34: The method according to any one of Exemplary Claims 32 or 33, wherein the crosslinking binder comprises a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

[0115] Exemplary Claim 35: The method according to any one of Exemplary Claims 32 to 34, wherein a ratio of pigment-to-binder ranges from about 0.2: 1 to about 20: 1.

[0116] Exemplary Claim 36: The acoustic panel according to any one of Exemplary Claims 32 to35, wherein the binder comprises vinyl acetate polymer.

[0117] Exemplary Claim 37: The acoustic panel according to any one of Exemplary Claims 32 to36, wherein the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.

[0118] Exemplary Claim 38: The acoustic panel according to any one of Exemplary Claims 32 to37, wherein the binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %, or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.

[0119] Exemplary Claim 39: The method according to any one of Exemplary Claims 32 to 38, wherein curing comprises drying the substrate at a temperature ranging from about 275 °F to about 480 °F.EXAMPLES

[0120] 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 20 °C.

[0121] The following Tables illustrate exemplary data collected regarding mechanical and material properties of fiberglass and mineral fiber boards coated with the above-described edge coating as further illustrated below.TABLE 1

[0122] The edge coating composition of Table 1 is the composition for Control 2 using a polyvinyl acetate binder that is not crosslinking. The composition has a filler to binder ratio of 1 and 61.9% solids.TABLE 2

[0123] The composition of Table 2 is the composition for Example 2 having a crosslinking binder and a filler to binder ratio of 1 : 1 and 55.9% solids.TABLE 3

[0124] The composition of Table 3 is the composition for Example 1 having a crosslinking binder and a filler to binder ratio of 6.03 and 58.8% solids.TABLE 4

[0125] The edge coating composition of Table 4 is the composition for Control 1 using a polyvinyl acetate binder that is not crosslinking. The composition has a filler to binder ratio of 6.03 and75.50% solids.TABLE 5crosslinking binder. The composition has a filler to binder ratio of 6.03 and 60.7% solids.TABLE 6

[0127] The edge coating composition of Table 6 is the composition for Example 4 using a crosslinking binder. The composition has a filler to binder ratio of 1 and 64% solids.

[0128] Referring to Table 7, the Examples above were tested for edge indent Strength comparison. The samples were indent tested with a metal blade with round edge at the diameter of 0.5 inch, and compression tested with an Instron at the speed of 0.5 inch per minute. It is desired that the panels can have high edge strength and durability in order to minimize or eliminate the product damage during manufacturing, handling, transportation, installation, and in service. The force required to indent the product is used to compare and prove the strength with different coatings. As shown in Table 7, Example 1 and Example 2 with crosslinking binders consistently exhibited higher required indent forces as compared to the control 1 with a binder is not crosslinking. The differences are much bigger at lower filler to binder ratio, which clearly demonstrates that beneficial improvement from the crosslinking binder. Example 4 exhibited a strength about seven times as control sample 2 at 0.20” indent depth.TABLE 7

[0129] 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 to those 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

CLAIMSWhat Is Claimed Is :

1. An acoustic panel comprising: a substrate having a first major surface opposite a second major surface and a side surface extending there-between; and a coating composition over the side surface of the substrate, the coating composition comprising: a pigment; and a crosslinking binder.

2. The acoustic panel according to claim 1, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.

3. The acoustic panel according to claim 1 or 2, wherein a ratio of pigment-to-binder ranges from about 0.2: 1 to about 20: 1.

4. The acoustic panel according to any one of claims 1 to 3, wherein the binder comprises vinyl acetate polymer.

5. The acoustic panel according to any one of claims 1 to 4, wherein the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.

6. The acoustic panel according to any one of claims 1 to 5, wherein the binder comprises a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

7. The acoustic panel according to any one of claims 1 to 6, wherein the binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %,or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.

8. The acoustic panel according to any one of claims 1 to 7, wherein the pigment comprises titanium dioxide present at a concentration of about 0.1 wt. % to about 35 wt. %, from about 0.5 wt. % to about 25 wt. %, or from about 1 wt. % to about 20 wt. %, based upon the dry weight of the coating composition.

9. The acoustic panel according to any one of claims 1 to 8, wherein the pigment comprises calcined diatomaceous earth 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 coating composition.

10. The acoustic panel according to any one of claims 1 to 9, wherein the pigment comprises aluminum hydroxide 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 coating composition.

11. The acoustic panel according to any one of claims 1 to 10, wherein the pigment comprises calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt. % to about 45 wt. %, or from about 27.0 wt. % to about 35 wt. %, based on the dry weight of the coating composition.

12. The acoustic panel according to any one of claims 1 to 11, wherein the coating composition further comprises water present in an amount from about 20 wt. % to about 60 wt. %, from about 30 wt. % to about 50 wt. %, or from about 40 wt. % to about 60 wt. %, based upon the wet weight of the coating composition.

13. The acoustic panel according to any one of claims 1 to 12, wherein the coating composition further comprises a hydrophobic polymer emulsion present in an amount from about 0.1wt. % 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 coating composition.

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

15. The acoustic panel according to any one of claims 1 to 14, wherein the coating composition further comprises 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 coating composition.

16. The acoustic panel according to any one of claims 1 to 15, wherein the coating composition further comprises a defoamer 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 coating composition.

17. The acoustic panel according to any one of claims 1 to 16, wherein the coating composition further comprises biocide present in an amount from about 0.01 wt. % to about 1 wt. %, from about 0.05 wt. % to about 0.8 wt. %, or from about 0.3 wt. % to about 0.7 wt. %, based on the dry weight of the coating composition.

18. The acoustic panel according to any of claims 1 to 17, wherein the pigment further comprises 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 coating composition.

19. The acoustic panel according to any one of claims 1 to 18, wherein the pigment further comprises a calcined extender present in an amount from about 1 wt. % to about 25 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 coating composition.

20. The acoustic panel according to any one of claims 1 to 19, wherein the acoustic panel is a ceiling or wall panel.

21. A method for forming an acoustic building panel, the method comprising: providing a substrate having a first major surface opposite a second major surface and a side surface extending there-between; applying a coating composition over the side surface, the coating composition comprising a crosslinking binder and a pigment; and curing the substrate to yield the acoustic building panel.

22. The method according to claim 21, wherein the crosslinking binder comprises a blend of two or more binders, wherein at least one of the two or more binders is a crosslinking binder, and wherein at least one of the two or more binders is not crosslinking.

23. The method according to any one of claims 21 or 22, wherein a ratio of pigment-to-binder ranges from about 0.2: 1 to about 20: 1.

24. The acoustic panel according to any one of claims 21 to 23, wherein the binder comprises a crosslinker present in an amount ranging from about 0.5 wt% to about 30 wt%, based on the total dry weight of the coating composition.

25. The acoustic panel according to any one of claims 21 to 24, wherein the binder is present in an amount from about 5 wt. % to about 70 wt. %, from about 10 wt. % to about 60 wt. %, or from about 30 wt. % to about 50 wt. %, based on the dry weight of the coating composition.

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