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WO2025096468A1 - Coating compositions for building panels - Google Patents

Coating compositions for building panels Download PDF

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Publication number
WO2025096468A1
WO2025096468A1 PCT/US2024/053455 US2024053455W WO2025096468A1 WO 2025096468 A1 WO2025096468 A1 WO 2025096468A1 US 2024053455 W US2024053455 W US 2024053455W WO 2025096468 A1 WO2025096468 A1 WO 2025096468A1
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WO
WIPO (PCT)
Prior art keywords
composition
present
coating composition
building panel
dry weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/053455
Other languages
French (fr)
Inventor
Tiffany EDNER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Armstrong World Industries Inc
Original Assignee
Armstrong World Industries Inc
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Filing date
Publication date
Application filed by Armstrong World Industries Inc filed Critical Armstrong World Industries Inc
Publication of WO2025096468A1 publication Critical patent/WO2025096468A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/61Additives non-macromolecular inorganic
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/65Additives macromolecular
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J131/00Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid, or of a haloformic acid; Adhesives based on derivatives of such polymers
    • C09J131/02Homopolymers or copolymers of esters of monocarboxylic acids
    • C09J131/04Homopolymers or copolymers of vinyl acetate
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20Oxides; Hydroxides
    • C08K3/22Oxides; Hydroxides of metals
    • C08K2003/2227Oxides; Hydroxides of metals of aluminium
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24Acids; Salts thereof
    • C08K3/26Carbonates; Bicarbonates
    • C08K2003/265Calcium, strontium or barium carbonate
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/30Sulfur-, selenium- or tellurium-containing compounds
    • C08K2003/3045Sulfates
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K2201/00Specific properties of additives
    • C08K2201/019Specific properties of additives the composition being defined by the absence of a certain additive
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/01Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013Fillers, pigments or reinforcing additives
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds
    • C08K3/346Clay

Definitions

  • the present disclosure is directed to coating compositions.
  • the disclosed coating composition includes a binder and a pigment blend,
  • the pigment blend includes barium sulfate.
  • the pigment and binder are present at a ratio of pigment-to-binder is from about 1:1 to about 20:1.
  • 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.
  • the binder includes vinyl acrylic polymer.
  • the pigment blend further includes titanium dioxide.
  • the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
  • the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide.
  • the pigment blend 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 composition.
  • the pigment blend includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt.
  • the pigment blend includes calcium carbonate 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.
  • the coating composition further includes a pigment extender.
  • the pigment extender includes barium sulfate.
  • the pigment extender is free from titanium dioxide.
  • 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.
  • the coating composition includes a wetting and dispersing additive includes an anionic copolymer.
  • the wetting and dispersing additive has an acid value of about 2 mg KOH/g.
  • the wetting and dispersing additive is present in an amount from about 0.1 wt. % to about 5 wt.
  • the coating composition includes 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.
  • the clay is a hectorite clay.
  • the coating composition includes a defoamer, such as a wax or 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.
  • the coating composition of 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.
  • 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.
  • 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.
  • the coating composition of 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.
  • the building panel includes a substrate having a first major surface opposite a second major surface and a coating over the first major surface.
  • the coating includes a binder and a pigment blend including barium sulfate.
  • the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
  • the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
  • a ratio of pigment-to-binder is from about 1:1 to about 20:1.
  • 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.
  • the binder includes vinyl acrylic polymer.
  • the pigment blend includes titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
  • the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide.
  • the pigment blend 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 composition.
  • the pigment blend 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.
  • the pigment blend includes calcium carbonate 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.
  • the coating includes a pigment extender.
  • the pigment extender includes barium sulfate.
  • the pigment extender is free from titanium dioxide.
  • the coating includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, freeze-thaw additive, precipitated synthetic silicate, or other filler.
  • the building panel is a ceiling panel or a wall panel.
  • the building panel includes a scrim positioned between the first major surface and the coating.
  • the building panel includes an adhesive adhering the first major surface of the substrate to the scrim.
  • the adhesive includes polyvinyl acetate emulsion.
  • the building panel has an NRC value of at least about 0.5.
  • the building panel of has a CAC value of at least about 46. In one example, the building panel has a light reflectance from about 0.05 to about 0.87. [0026] In one example, the coating on the building panel demonstrates a hiding power of about 0.99. In one example, the coating is applied in an amount ranging from about 40 g/ft 2 to about 60 g/ft 2 . In one example, the building panel includes at least two coatings applied to the building panel, at least three coatings applied to the building panel, or at least four coatings applied to the building panel. [0027] Also disclosed are surface covering systems.
  • the surface covering system includes a plurality of building panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of building panels, each building panel includes a substrate having a first major surface opposite a second major surface, a seam-filling material configured to be applied to each of the plurality of seams, and a coating composition configured to be applied to the plurality of building panels and the seam-filling material.
  • the coating composition includes a binder and a pigment blend.
  • the pigment blend includes barium sulfate.
  • the substrate of the surface covering system includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
  • the substrate of the surface covering system has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
  • the seam-filling material includes gypsum plaster.
  • the a ratio of pigment- to-binder is from about 1:1 to about 20:1.
  • 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.
  • the binder includes vinyl acrylic polymer.
  • the pigment blend includes titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
  • the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide.
  • the pigment blend 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 composition.
  • the pigment blend includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt.
  • the pigment blend includes calcium carbonate 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.
  • the coating includes a pigment extender.
  • the pigment extender includes barium sulfate.
  • the pigment extender is free from titanium dioxide.
  • the coating includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.
  • the surface covering system is a ceiling panel or a wall panel.
  • each building panel of the plurality of building panels includes a scrim positioned between the first major surface and the coating.
  • each building panel of the plurality of building panels includes an adhesive adhering the first major surface of the substrate to the scrim.
  • the adhesive includes polyvinyl acetate emulsion.
  • the plurality of building panels have an average NRC value of at least about 0.5.
  • the plurality of building panels have an average CAC value of at least about 46.
  • the plurality of building panels have an average light reflectance from about 0.05 to about 0.87.
  • the coating demonstrates a hiding power of about 0.99. In one example, the coating is applied in an amount ranging from about 40 g/ft 2 to about 60 g/ft 2 .
  • the surface covering system includes at least two coatings applied to the plurality of building panels and the seam-filling material, at least three coatings applied to the plurality of building panels and the seam-filling material, or at least four coatings applied to the plurality of building panels and the seam-filling material.
  • Figure 1 is a top perspective view of an building panel according to an example of the present disclosure
  • Figure 2 is a cross-sectional view of an building panel of the present disclosure
  • Figure 3 is a cross-sectional view of an building panel of the present disclosure
  • Figure 4 is a top perspective view of a surface covering system according to an example of the present disclosure
  • Figure 5 is a cross-sectional view of a surface covering system of the present disclosure
  • Figure 6 is an emissivity graph of several building panels
  • Figure 7 is an emissivity graph of several building panels.
  • 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. Thus, any range of values disclosed herein is merely exemplary and includes all values and sub-ranges there-between [0048] 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.
  • 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.
  • 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.
  • 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.
  • use of the term “about” in conjunction with a numeral value refers to a value that may be +/- 5% of that numeral.
  • 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.
  • 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.
  • a coating composition 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. [0053] Disclosed herein is a coating composition.
  • the coating composition may be used on building panels, such as building panels for ceilings and walls.
  • the composition is designed to advantageously offer sufficient aesthetic properties while maintaining desired acoustic properties and improving environmental impact as compared to coating compositions having higher concentrations of titanium dioxide.
  • the coating composition includes a binder.
  • 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.
  • the binder comprises vinyl acrylic polymer.
  • the coating composition further includes a pigment blend.
  • the pigment blend includes titanium dioxide barium sulfate. The titanium dioxide and barium sulfate may be present at a ratio from about 1:1 to about 1:5.
  • the titanium dioxide and barium sulfate are present at a ratio of about 1:1 such that approximately 50% of the titanium typically used in the coating is replaced by barium sulfate.
  • the barium sulfate is added to the coating composition in a dry powder form.
  • the barium sulfate is added to the coating composition as a slurry.
  • the barium sulfate is added to the coating composition in a dry powder form and as a slurry.
  • the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the ratio of pigment-to-binder is selectively controlled based upon the intended application. In one example, a ratio of pigment-to-binder is from about 1:1 to about 20:1.
  • the ratio of pigment-to-binder is form about 1:1 to about 10:1. In yet another example, the ratio of pigment-to-binder is from about 1:1 to about 5:1.
  • the pigment blend of the coating composition may include one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. In one example, pigment blend 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 composition.
  • the pigment blend 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 composition.
  • the pigment blend includes calcium carbonate 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.
  • the coating composition may further include a pigment extender.
  • the pigment extender comprises barium sulfate.
  • the barium sulfate may be in the form of a dry powder or may be a slurry.
  • the pigment extender is free from titanium dioxide.
  • the coating composition may further include a hydrophobic polymer emulsion.
  • 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.
  • the composition further may further include a wetting and dispersing additive comprising an anionic copolymer.
  • the wetting and dispersing additive has an acid value of about 2 mg KOH/g.
  • 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.
  • the coating compotation requires less dispersant to suspend barium sulfate as compared to titanium dioxide.
  • the coating composition may further include clay.
  • 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.
  • the clay is a hectorite clay.
  • the clay is a kaolin clay.
  • the coating composition may further include a defoamer.
  • the defoamer comprises wax and mineral oil.
  • the defoamer is present in an amount from about 0.01 wt. % to about 2 wt. %, from about 0.01 wt.
  • the coating composition may further include one or more biocides.
  • 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.
  • the coating composition may further include precipitated synthetic silicate. In one example, the precipitated synthetic silicate is present in an amount from 1 wt. % to about 5 wt.
  • the coating composition may further include a calcined extender.
  • 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.
  • the coating composition may further include a liquid, such as water.
  • 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.
  • a building panel 100 such as a wall panel or a ceiling panel.
  • the building panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114.
  • the substrate 110 may further have a side surface 116 that extends between the first major surface 112 and the second major surface 114.
  • the substrate 110 includes one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
  • the substrate 110 has an airflow resistance as required by the desired acoustic properties of the substrate. In one example, the substrate 110 has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
  • the building panel 100 may have a panel thickness t 0 as measured from the first major surface 112 to the second major surface 114.
  • the panel thickness t 0 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-between.
  • 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 100 may vary. In certain examples, the density of the building panel 100 is from about 0.3 g/cm 3 to about 1.5 g/cm 3 . In certain examples, the building panel 100 density is from about 0.4 g/cm 3 to about 0.9 g/cm 3 . In further examples, the building panel density is from about 0.5 g/cm 3 to about 0.7 g/cm 3 .
  • the building panel 100 includes a coating 130 over the first major surface of the substrate 110.
  • the coating includes a binder and a pigment blend.
  • a ratio of pigment-to-binder is from about 1:1 to about 20:1.
  • 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.
  • the pigment blend of the coating 130 includes titanium dioxide and barium sulfate.
  • the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
  • the barium sulfate is added to the coating composition in a dry powder form.
  • the barium sulfate is added to the coating composition as a slurry.
  • the barium sulfate is added to the coating composition in a dry powder form and as a slurry.
  • the pigment blend may further include one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide.
  • the pigment blend comprises calcined diatomaceous earth present in an amount from about 3 wt. % to about 20 wt.
  • the pigment blend 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 composition of the coating 130.
  • the pigment blend comprises calcium carbonate present in an amount from about 20 wt. % to about 60 wt. %, from about 25 wt.
  • the coating 130 further includes pigment extender.
  • the pigment extender includes barium sulfate.
  • the pigment extender is free from titanium dioxide.
  • the coating 130 may include one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, freeze-thaw additive, precipitated synthetic silicate or other filler.
  • the building panel 100 may further include a scrim 120 having a first major scrim surface 122 and a second major scrim surface 124 coupled to the first major surface 112 of the substrate 110 positioned between the first major surface 112 and the coating 130.
  • the scrim 120 may be a filled scrim 120 or unfilled scrim 120.
  • the scrim 120 is coupled to the substrate 110 via an adhesive adhering the first major surface 112 of the substrate 110 to the scrim 120.
  • the adhesive comprises polyvinyl acetate emulsion.
  • the scrim 120 has a thickness t2 defined as the distance between the first major scrim surface 122 and the second major scrim surface 124.
  • the scrim 120 has a thickness t 2 from about 0.5 mm to about 0.8 mm.
  • the building panel 100 may be characterized by its acoustic properties.
  • panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinations thereof, or other.
  • panels have a sufficiently high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating to be characterized as an acoustical substrate 110 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.
  • the building panel 100 has an NRC value of at least about 0.5.
  • the building panel 100 has a CAC value of at least about 46.
  • the building panel 100 may be further characterized by its color and light reflectance properties.
  • the building panel 100 exhibits a light reflectance from about 0.05 to about 0.87.
  • the coating 130 of the building panel 100 demonstrates a hiding power of about 0.99, wherein a perfect hiding power value is 1.
  • the coating 130 is applied to the substrate 110 in an amount ranging from about 40 g/ft 2 to about 60 g/ft 2 .
  • the building panel 100 includes at least two coatings applied to the building panel 100, at least three coatings applied to the building panel 100, or at least four coatings applied to the building panel 100. Each coating 130 may have be applied in an amount ranging from about 40 g/ft 2 to about 60 g/ft 2 .
  • a surface covering system 200 may be a wall system or ceiling system.
  • the surface covering system 200 includes a plurality of building panels 205, such as building panel 100, configured to be positioned adjacent to each other. When positioned adjacent to each other, the plurality of building panels 205 form a plurality of seams between each of the plurality of building panels 205. [0087]
  • Each building panel 205 ⁇ of the plurality of building panels 205 includes a substrate 210 having a first major surface 212 opposite a second major surface 214.
  • each substrate 210 of the plurality of building panels 205 of the surface covering system 200 comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
  • each substrate 210 has an average airflow resistance from about 300 mks rayls to about 700 mks rayls.
  • the surface covering system 200 further includes a seam-filling material configured to be applied to each of the plurality of seams 215.
  • the seam-filling material, or joint compound, is configured to be applied to each seam 215 ⁇ of the plurality of seams 215.
  • the seam-filling material is configured to couple or join two acoustic panels 205 ⁇ to each other.
  • the seam-filling material comprises gypsum plaster.
  • the surface covering system 200 includes a coating composition configured to be applied to the plurality of building panels 205 and the seam-filling material to form a coating 230.
  • the coating composition includes a binder and a pigment blend.
  • a ratio of pigment-to-binder is from about 1:1 to about 20:1.
  • 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.
  • the binder comprises vinyl acrylic polymer.
  • the pigment blend includes titanium dioxide and barium sulfate.
  • the titanium dioxide and barium sulfate may be present at a ratio of about 1:1 such that half of the amount of titanium dioxide typically used is replaced with barium sulfate.
  • the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
  • the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
  • the barium sulfate is added to the coating composition in a dry powder form.
  • the barium sulfate is added to the coating composition as a slurry.
  • the barium sulfate is added to the coating composition in a dry powder form and as a slurry.
  • the pigment blend of the coating composition further includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide.
  • pigment blend of the coating composition 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 composition.
  • the pigment blend of the coating composition includes aluminum hydroxide present in an amount from about 3 wt. % to about 20 wt. %, from about 5 wt.
  • the pigment blend of the coating composition includes calcium carbonate 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.
  • the pigment blend of the coating composition includes a pigment extender.
  • the pigment extender may include barium sulfate.
  • the pigment extender is free from titanium dioxide.
  • the coating composition of the system 200 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, rheology modifier, tint, anitfungal, or precipitated synthetic silicate.
  • each building panel 205 ⁇ of the plurality of building panels 205 of the system 200 includes a scrim 220 having a first major scrim surface 222 and a second major scrim surface 224 coupled to the first major surface 212 of the substrate 210.
  • the scrim 220 has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
  • the scrim 220 may be a fiberglass scrim, or comprised of another fiber mesh.
  • the scrim 220 may be positioned between the first major surface 212 of the substrate 210 and the coating 230.
  • the surface covering system 200 includes an adhesive adhering the first major surface 212 of the substrate 210 to the scrim 220.
  • the adhesive comprises polyvinyl acetate emulsion.
  • the surface covering system 200 may be further characterized by the acoustic properties of the plurality of acoustic panels 205.
  • the plurality of acoustic panels 205 has an average NRC value of at least about 0.8. In another example, the plurality of acoustic panels 205 has an average CAC value of at least about 46.
  • the surface covering system 200 may be further characterized by a color difference between the seam-filling mater, or joint compound, and the plurality of building panels 205. In one example, a color difference in whiteness, L*, between the plurality of acoustic panels and the seam-filling material is from about 1 to about 6. In another example, the plurality of acoustic panels 205 has an average light reflectance from about 0.05 to about 0.87.
  • the coating 230 of the surface covering system 200 demonstrates a hiding power of about 0.99.
  • the coating 230 may be applied to the plurality of building panels 205 and seam-filling material of the surface covering system 200 at any thickness needed to achieve desired acoustic and aesthetic properties.
  • the coating 230 is applied in an amount ranging from about 40 g/ft 2 to about 60 g/ft 2 .
  • Example 9 demonstrates a composition having 100% TiO 2 pigment extender replaced with BaSO 4 in a slurry form.
  • Example 10 demonstrates a composition having 100% TiO2 pigment extender replaced with BaSO4 and 50% TiO2 replaced by BaSO4, both in a slurry form.
  • C olor (d G e g lo r s e s e ) 5 .1 .1 .5 .5 .3 .4 .1 d erence was deeced or e vaues beween e xampes and e Compara ves.
  • Table 10 illustrates color values and Delta E between Comparative compositions and Example compositions, as well as gloss values for Comparatives and Examples.
  • TABLE 11 Initial Final Delta b (initial vs Delta E red to their Comparatives.
  • FIG. 6 and 7 illustrate spectral emissivity testing data for a coating on the back of a tile. Testing included 2 different back coatings with different application rates (100 grams per board & 50 grams per board).
  • Formula 1 included 50% Barium sulfate, 50% binder and Formula 2 included 25% Barium sulfate, 75% binder. As shown in the graphs, it was observed that there is about a 75% statistical change of detecting a difference between compositions including barium sulfate and those without. [0116] During experimentation, it was found that barium sulfate-containing compositions were easier to suspend in solution than the comparative compositions not including barium sulfate. It was further observed that finished products having compositions containing barium sulfate exhibited improved performance as compared to those not containing barium sulfate. Additionally, it was observed that the coating computations required less dispersant to suspend barium sulfate than required to suspend titanium dioxide.

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Abstract

Disclosed herein is a coating composition having a binder and a pigment blend. The pigment blend includes barium sulfate. Also disclosed are building panels and surface covering systems.

Description

COATING COMPOSITIONS FOR BUILDING PANELS CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63/546568 filed on October 31, 2023, the disclosure of which is incorporated herein by reference in its entirety. FIELD OF DISCLOSURE [0002] The present disclosure relates to coating compositions for building panels, and more particularly to coating compositions having barium sulfate. 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 coating compositions for building panels. BRIEF 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] The present disclosure is directed to coating compositions. [0007] In one example, the disclosed coating composition includes a binder and a pigment blend, The pigment blend includes barium sulfate. The pigment and binder are present at a ratio of pigment-to-binder is from about 1:1 to about 20:1. [0008] In one example, 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 one example the binder includes vinyl acrylic polymer. [0009] In one example, the pigment blend further includes titanium dioxide. The titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5. In one example, the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. [0010] In one example, the pigment blend 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 composition. In one example, the pigment blend 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 composition. In one example, the pigment blend includes calcium carbonate 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. [0011] In one example, the coating composition further includes a pigment extender. one example, the pigment extender includes barium sulfate. In one example, the pigment extender is free from titanium dioxide. [0012] In one example, 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. [0013] In one example, the coating composition includes a wetting and dispersing additive includes an anionic copolymer. In one example, the wetting and dispersing additive has 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. %, 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. [0014] In one example, the coating composition includes 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 one example, the clay is a hectorite clay. [0015] In one example, the coating composition includes a defoamer, such as a wax or 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. [0016] In one example, the coating composition of 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 one example, 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 one example, 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 one example, the coating composition of 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. [0017] Also disclosed are building panels. [0018] In one example, the building panel includes a substrate having a first major surface opposite a second major surface and a coating over the first major surface. The coating includes a binder and a pigment blend including barium sulfate. [0019] In one example, the substrate includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In one example, the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls. In one example, a ratio of pigment-to-binder is from about 1:1 to about 20:1. In one example, 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 one example, the binder includes vinyl acrylic polymer. [0020] In one example, the pigment blend includes titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5. [0021] In one example, the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. In one example, the pigment blend 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 composition. In one example, the pigment blend 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 composition. In one example, the pigment blend includes calcium carbonate 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. [0022] In one example, the coating includes a pigment extender. In one example, the pigment extender includes barium sulfate. In one example, the pigment extender is free from titanium dioxide. [0023] In one example, the coating includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, freeze-thaw additive, precipitated synthetic silicate, or other filler. [0024] In one example, the building panel is a ceiling panel or a wall panel. In one example, the building panel includes a scrim positioned between the first major surface and the coating. In one example, the building panel includes an adhesive adhering the first major surface of the substrate to the scrim. In one example, the adhesive includes polyvinyl acetate emulsion. [0025] In one example, the building panel has an NRC value of at least about 0.5. In one example, the building panel of has a CAC value of at least about 46. In one example, the building panel has a light reflectance from about 0.05 to about 0.87. [0026] In one example, the coating on the building panel demonstrates a hiding power of about 0.99. In one example, the coating is applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2. In one example, the building panel includes at least two coatings applied to the building panel, at least three coatings applied to the building panel, or at least four coatings applied to the building panel. [0027] Also disclosed are surface covering systems. [0028] In one example, the surface covering system includes a plurality of building panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of building panels, each building panel includes a substrate having a first major surface opposite a second major surface, a seam-filling material configured to be applied to each of the plurality of seams, and a coating composition configured to be applied to the plurality of building panels and the seam-filling material. The coating composition includes a binder and a pigment blend. The pigment blend includes barium sulfate. [0029] In one example, the substrate of the surface covering system includes mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In one example, the substrate of the surface covering system has an airflow resistance from about 300 mks rayls to about 700 mks rayls. In one example, the seam-filling material includes gypsum plaster. In one example, the a ratio of pigment- to-binder is from about 1:1 to about 20:1. In one example, 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 one example, the binder includes vinyl acrylic polymer. [0030] In one example, the pigment blend includes titanium dioxide present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In one example, the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5. [0031] In one example, the pigment blend includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. In one example, the pigment blend 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 composition. In one example, the pigment blend 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 composition. In one example, the pigment blend includes calcium carbonate 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. [0032] In one example, the coating includes a pigment extender. In one example, the pigment extender includes barium sulfate. In one example, the pigment extender is free from titanium dioxide. In one example, the coating includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate. [0033] In one example, the surface covering system is a ceiling panel or a wall panel. In one example, each building panel of the plurality of building panels includes a scrim positioned between the first major surface and the coating. In one example, each building panel of the plurality of building panels includes an adhesive adhering the first major surface of the substrate to the scrim. In one example, the adhesive includes polyvinyl acetate emulsion. [0034] In one example, the plurality of building panels have an average NRC value of at least about 0.5. [0035] In one example, the plurality of building panels have an average CAC value of at least about 46. In one example, the plurality of building panels have an average light reflectance from about 0.05 to about 0.87. [0036] In one example, the coating demonstrates a hiding power of about 0.99. In one example, the coating is applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2. In one example, the surface covering system includes at least two coatings applied to the plurality of building panels and the seam-filling material, at least three coatings applied to the plurality of building panels and the seam-filling material, or at least four coatings applied to the plurality of building panels and the seam-filling material. DESCRIPTION OF THE DRAWINGS [0037] Figure 1 is a top perspective view of an building panel according to an example of the present disclosure; [0038] Figure 2 is a cross-sectional view of an building panel of the present disclosure; [0039] Figure 3 is a cross-sectional view of an building panel of the present disclosure; [0040] Figure 4 is a top perspective view of a surface covering system according to an example of the present disclosure; [0041] Figure 5 is a cross-sectional view of a surface covering system of the present disclosure; [0042] Figure 6 is an emissivity graph of several building panels; and [0043] Figure 7 is an emissivity graph of several building panels. [0044] 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. DETAILED DESCRIPTION [0045] 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. [0046] 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 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”. [0047] 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. Thus, any range of values disclosed herein is merely exemplary and includes all values and sub-ranges there-between [0048] 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. [0049] 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. [0050] 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. [0051] 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. [0052] 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. [0053] Disclosed herein is a coating composition. The coating composition may be used on building panels, such as building panels for ceilings and walls. The composition is designed to advantageously offer sufficient aesthetic properties while maintaining desired acoustic properties and improving environmental impact as compared to coating compositions having higher concentrations of titanium dioxide. [0054] In one or more examples, the coating composition includes a binder. In one example, 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 one or more examples, the binder comprises vinyl acrylic polymer. [0055] The coating composition further includes a pigment blend. In one example, the pigment blend includes titanium dioxide barium sulfate. The titanium dioxide and barium sulfate may be present at a ratio from about 1:1 to about 1:5. In another example, the titanium dioxide and barium sulfate are present at a ratio of about 1:1 such that approximately 50% of the titanium typically used in the coating is replaced by barium sulfate. [0056] In one example, the barium sulfate is added to the coating composition in a dry powder form. In another example, the barium sulfate is added to the coating composition as a slurry. In yet another example, the barium sulfate is added to the coating composition in a dry powder form and as a slurry. [0057] In one or more examples, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. [0058] In one or more examples, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. [0059] The ratio of pigment-to-binder is selectively controlled based upon the intended application. In one example, a ratio of pigment-to-binder is from about 1:1 to about 20:1. In another example, the ratio of pigment-to-binder is form about 1:1 to about 10:1. In yet another example, the ratio of pigment-to-binder is from about 1:1 to about 5:1. [0060] In one or more examples, the pigment blend of the coating composition may include one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. In one example, pigment blend 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 composition. [0061] In one or more examples, the pigment blend 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 composition. [0062] In one or more examples, the pigment blend includes calcium carbonate 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. [0063] The coating composition may further include a pigment extender. In one example, the pigment extender comprises barium sulfate. The barium sulfate may be in the form of a dry powder or may be a slurry. In another example, the pigment extender is free from titanium dioxide. [0064] The coating composition may further include 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. %, 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. [0065] The composition further may further include 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. In another 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 composition. In one or more examples, the coating compotation requires less dispersant to suspend barium sulfate as compared to titanium dioxide. [0066] The coating composition may further include 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 composition. in one example, the clay is a hectorite clay. In another example, the clay is a kaolin clay. [0067] The coating composition may further include a defoamer. In one example, the defoamer comprises wax and mineral oil. In another 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 composition. [0068] The coating composition may further include one or more biocides. 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. [0069] The coating composition may further include 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 composition. [0070] The coating composition may further include a calcined extender. In one example, 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. [0071] The coating composition may further include a liquid, such as water. In one example, 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. [0072] Referring to Figure 1, Figure 2, and Figure 3, also disclosed is a building panel 100, such as a wall panel or a ceiling panel. The building panel 100 includes a substrate 110 having a first major surface 112 opposite a second major surface 114. The substrate 110 may further have a side surface 116 that extends between the first major surface 112 and the second major surface 114. [0073] In one example, the substrate 110 includes one or more of mineral fiber board, fiberglass, jute fiber, wood, or a composite material. The substrate 110 has an airflow resistance as required by the desired acoustic properties of the substrate. In one example, the substrate 110 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. [0074] The building panel 100 may have a panel thickness t0 as measured from the first major surface 112 to the second major surface 114. 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-between. 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 100 may vary. In certain examples, the density of the building panel 100 is from about 0.3 g/cm3 to about 1.5 g/cm3. In certain examples, the building panel 100 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 to about 0.7 g/cm3. [0075] Referring to Figure 3, the building panel 100 includes a coating 130 over the first major surface of the substrate 110. The coating includes a binder and a pigment blend. In one example, a ratio of pigment-to-binder is from about 1:1 to about 20:1. In one example, 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 another example, comprises vinyl acrylic polymer. [0076] In one or more examples, the pigment blend of the coating 130 includes titanium dioxide and barium sulfate. In one example, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. [0077] In another example, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. In yet another example, the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5. [0078] In one example, the barium sulfate is added to the coating composition in a dry powder form. In another example, the barium sulfate is added to the coating composition as a slurry. In yet another example, the barium sulfate is added to the coating composition in a dry powder form and as a slurry. [0079] The pigment blend may further include one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. In one example, the pigment blend 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 composition. In another example, the pigment blend 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 composition of the coating 130. In yet another example, the pigment blend comprises calcium carbonate 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. [0080] In one or more examples, the coating 130 further includes pigment extender. The pigment extender includes barium sulfate. In one example, the pigment extender is free from titanium dioxide. [0081] The coating 130 may include one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, freeze-thaw additive, precipitated synthetic silicate or other filler. [0082] Still referring to Figure 2, in one or more examples, the building panel 100 may further include a scrim 120 having a first major scrim surface 122 and a second major scrim surface 124 coupled to the first major surface 112 of the substrate 110 positioned between the first major surface 112 and the coating 130. The scrim 120 may be a filled scrim 120 or unfilled scrim 120. In one example, the scrim 120 is coupled to the substrate 110 via an adhesive adhering the first major surface 112 of the substrate 110 to the scrim 120. In one example, the adhesive comprises polyvinyl acetate emulsion. The scrim 120 has a thickness t2 defined as the distance between the first major scrim surface 122 and the second major scrim surface 124. In one or more examples, the scrim 120 has a thickness t2 from about 0.5 mm to about 0.8 mm. [0083] The building panel 100 may be characterized by its acoustic properties. 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 110 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 example, the building panel 100 has an NRC value of at least about 0.5. In another example, the building panel 100 has a CAC value of at least about 46. [0084] The building panel 100 may be further characterized by its color and light reflectance properties. In one example, the building panel 100 exhibits a light reflectance from about 0.05 to about 0.87. In another example, the coating 130 of the building panel 100 demonstrates a hiding power of about 0.99, wherein a perfect hiding power value is 1. [0085] In one or more examples, the coating 130 is applied to the substrate 110 in an amount ranging from about 40 g/ft2 to about 60 g/ft2. In another example, the building panel 100 includes at least two coatings applied to the building panel 100, at least three coatings applied to the building panel 100, or at least four coatings applied to the building panel 100. Each coating 130 may have be applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2. [0086] Referring to Figure 4 and Figure 5, also disclosed is a surface covering system 200. The surface covering system 200 may be a wall system or ceiling system. In one example, the surface covering system 200 includes a plurality of building panels 205, such as building panel 100, configured to be positioned adjacent to each other. When positioned adjacent to each other, the plurality of building panels 205 form a plurality of seams between each of the plurality of building panels 205. [0087] Each building panel 205` of the plurality of building panels 205 includes a substrate 210 having a first major surface 212 opposite a second major surface 214. In one or more examples, each substrate 210 of the plurality of building panels 205 of the surface covering system 200 comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material. In another example, each substrate 210 has an average airflow resistance from about 300 mks rayls to about 700 mks rayls. [0088] In one or more examples, the surface covering system 200 further includes a seam-filling material configured to be applied to each of the plurality of seams 215. The seam-filling material, or joint compound, is configured to be applied to each seam 215` of the plurality of seams 215. The seam-filling material is configured to couple or join two acoustic panels 205` to each other. In one example, the seam-filling material comprises gypsum plaster. [0089] Still referring to Figure 5, the surface covering system 200 includes a coating composition configured to be applied to the plurality of building panels 205 and the seam-filling material to form a coating 230. The coating composition includes a binder and a pigment blend. In one example, a ratio of pigment-to-binder is from about 1:1 to about 20:1. In one example, 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 another example, the binder comprises vinyl acrylic polymer. [0090] In one or more examples, the pigment blend includes titanium dioxide and barium sulfate. The titanium dioxide and barium sulfate may be present at a ratio of about 1:1 such that half of the amount of titanium dioxide typically used is replaced with barium sulfate. In another example, the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5. [0091] In one example, the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. [0092] In another example, the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. [0093] In one example, the barium sulfate is added to the coating composition in a dry powder form. In another example, the barium sulfate is added to the coating composition as a slurry. In yet another example, the barium sulfate is added to the coating composition in a dry powder form and as a slurry. [0094] In one or more examples, the pigment blend of the coating composition further includes one or more of calcium carbonate, calcined diatomaceous earth, and aluminum hydroxide. [0095] In one example, pigment blend of the coating composition 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 composition. [0096] In one example, the pigment blend of the coating composition 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 composition. [0097] In one example, the pigment blend of the coating composition includes calcium carbonate 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. [0098] In one or more examples, the pigment blend of the coating composition includes a pigment extender. The pigment extender may include barium sulfate. In another example, the pigment extender is free from titanium dioxide. [0099] In one or more examples, the coating composition of the system 200 includes one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, rheology modifier, tint, anitfungal, or precipitated synthetic silicate. [0100] Referring to Figure 5, each building panel 205` of the plurality of building panels 205 of the system 200 includes a scrim 220 having a first major scrim surface 222 and a second major scrim surface 224 coupled to the first major surface 212 of the substrate 210. In one or more examples, the scrim 220 has an airflow resistance from about 300 mks rayls to about 700 mks rayls. The scrim 220 may be a fiberglass scrim, or comprised of another fiber mesh. The scrim 220 may be positioned between the first major surface 212 of the substrate 210 and the coating 230. [0101] In one or more examples, the surface covering system 200 includes an adhesive adhering the first major surface 212 of the substrate 210 to the scrim 220. In one example, the adhesive comprises polyvinyl acetate emulsion. [0102] The surface covering system 200 may be further characterized by the acoustic properties of the plurality of acoustic panels 205. In one example, the plurality of acoustic panels 205 has an average NRC value of at least about 0.8. In another example, the plurality of acoustic panels 205 has an average CAC value of at least about 46. [0103] The surface covering system 200 may be further characterized by a color difference between the seam-filling mater, or joint compound, and the plurality of building panels 205. In one example, a color difference in whiteness, L*, between the plurality of acoustic panels and the seam-filling material is from about 1 to about 6. In another example, the plurality of acoustic panels 205 has an average light reflectance from about 0.05 to about 0.87. In yet another example, the coating 230 of the surface covering system 200 demonstrates a hiding power of about 0.99. [0104] The coating 230 may be applied to the plurality of building panels 205 and seam-filling material of the surface covering system 200 at any thickness needed to achieve desired acoustic and aesthetic properties. In one example, the coating 230 is applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2. In another example, at least two coatings applied to the plurality of building panels 205 and the seam-filling material, at least three coatings applied to the plurality of building panels 205 and the seam-filling material, or at least four coatings applied to the plurality of building panels 205 and the seam-filling material. EXAMPLES [0105] 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. [0106] Various compositions of the disclosure were tested for differences in physical, material, and aesthetic properties, including color, viscosity, emissivity, and pH. The example compositions, having about 50% of the titanium dioxide replaced with barium sulfate, were compared to Comparative compositions having no barium sulfate. Tables 1 to 7 include compositional data for each example and Comparative. TABLE 1 Example 1 Comparative 1 Com onent % Raw Mass % Raw Mass
Figure imgf000019_0001
TABLE 2 Example 2 Comparative 2
Figure imgf000019_0002
Defoamer 0.05% 0.05% Dispersant 0.79% 1.1%
Figure imgf000020_0001
Example 3 Comparative 3 % Raw Mass
Figure imgf000020_0002
TABLE 4 Example 4 Comparative 4
Figure imgf000020_0003
Calcium Carbonate Slurry 36.77% 36.77% Defoamer 0.07% 0.07%
Figure imgf000021_0001
5 Example 5 Comparative 5 Function % Raw Mass % Raw Mass
Figure imgf000021_0002
TABLE 6 Example 6 Comparative 6
Figure imgf000021_0003
Dispersant 0.10% 0.10% Titanium Dioxide 0.47% 0.94%
Figure imgf000022_0001
Example 7 Comparative 7 Function % Raw Mass % Raw Mass
Figure imgf000022_0002
TABLE 8 Example 8 Example 9 Example 10 % R M % R M s
Figure imgf000022_0003
Tint 0.00% 0.00% 0.00%
Figure imgf000023_0001
ith BaSO4 and 50% TiO2 replaced by BaSO4, both in a solid powder form. Example 9 demonstrates a composition having 100% TiO2 pigment extender replaced with BaSO4 in a slurry form. Example 10 demonstrates a composition having 100% TiO2 pigment extender replaced with BaSO4 and 50% TiO2 replaced by BaSO4, both in a slurry form. TABLE 9 Color (d G eg lo rs es e) 5 .1 .1 .5 .5 .3 .4 .1
Figure imgf000023_0002
d erence was deeced or e vaues beween e xampes and e Compara ves. TABLE 10 Color Gloss (degree)
Figure imgf000023_0003
[0109] Table 10 illustrates color values and Delta E between Comparative compositions and Example compositions, as well as gloss values for Comparatives and Examples. TABLE 11 Initial Final Delta b (initial vs Delta E red
Figure imgf000024_0001
to their Comparatives. TABLE 12 Liquid Coating Color & Gloss mple 2 28 50 00 80 0 4 11
Figure imgf000024_0002
A -0.62 -0.56 -0.60 -0.56 -0.58 -0.58 -0.61 -0.63 -0.68 -0.66 -0.40 -0.32 -0.57 -0.50 B 2.10 2.14 2.05 2.02 1.70 1.70 2.98 3.36 2.04 2.06 1.05 0.87 1.20 1.12 19
Figure imgf000025_0001
of 50% of titanium dioxide with barium sulfate had minimal to no impact on pH, % solids, density, viscosity, and color values. TABLE 13 Jar Testing : Hand Sprayed Material Initial Final Delta b E 2 4 8 9 9 3 2 3 9 ive
Figure imgf000025_0002
compositions. As shown in the table, replacement of 50% of titanium dioxide with barium sulfate had minimal to no impact on color values. TABLE 14 Jar Testing : Plant Production Material b 3 4 1 3
Figure imgf000025_0003
1 composition. As shown in the table, replacement of 50% of titanium dioxide with barium sulfate had minimal to no impact on color values. TABLE 14 Jar Testing : Pilot Plant Material in
Figure imgf000026_0001
in the table, replacement of 50% of titanium dioxide with barium sulfate had minimal to no impact on color values. [0115] Figures 6 and 7 illustrate spectral emissivity testing data for a coating on the back of a tile. Testing included 2 different back coatings with different application rates (100 grams per board & 50 grams per board). Formula 1 included 50% Barium sulfate, 50% binder and Formula 2 included 25% Barium sulfate, 75% binder. As shown in the graphs, it was observed that there is about a 75% statistical change of detecting a difference between compositions including barium sulfate and those without. [0116] During experimentation, it was found that barium sulfate-containing compositions were easier to suspend in solution than the comparative compositions not including barium sulfate. It was further observed that finished products having compositions containing barium sulfate exhibited improved performance as compared to those not containing barium sulfate. Additionally, it was observed that the coating computations required less dispersant to suspend barium sulfate than required to suspend titanium dioxide. [0117] 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

CLAIMS What is Claimed Is: 1. A coating composition comprising: a binder; and a pigment blend, wherein the pigment blend comprises: barium sulfate; wherein a ratio of pigment-to-binder is from about 1:1 to about 20:1.
2. The coating composition of claim 1, 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.
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 pigment blend further comprises titanium dioxide, and wherein the titanium dioxide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition. 5. The coating composition of any one of claims 1 to 4, wherein the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.
5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
6. The coating composition of any one of claims 4 to 5, wherein the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
7. The coating composition of any one of claims 1 to 6, wherein the pigment blend further comprises one or more of: calcium carbonate; calcined diatomaceous earth; and aluminum hydroxide.
8. The coating composition of any one of claims 1 to 7, wherein the pigment blend 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 composition.
9. The coating composition of any one of claims 1 to 8 wherein the pigment blend 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 composition.
10. The coating composition of any one of claims 1 to 9, wherein the pigment blend comprises calcium carbonate 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.
11. The coating composition of any one of claims 1 to 10, further comprising a pigment extender.
12. The coating composition of claim 11, wherein the pigment extender comprises barium sulfate.
13. The coating composition of any one of claims 11 to 12, wherein the pigment extender is free from titanium dioxide.
14. The coating composition of any one of claims 1 to 13, further comprising a hydrophobic polymer emulsion.
15. The coating composition of 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 composition.
16. The coating composition of any one of claims 1 to 15, wherein the composition further comprises a wetting and dispersing additive comprising an anionic copolymer.
17. The coating composition of claim 16, wherein the wetting and dispersing additive has an acid value of about 2 mg KOH/g.
18. The coating composition of any one of claims 16 or 17, 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.
19. The coating composition of any one of claims 1 to 18 further comprising clay.
20. The coating composition of 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 composition.
21. The coating composition of any of claims 19 to 20, wherein the clay is a hectorite clay.
22. The coating composition of any one of claims 1 to 18, further comprising a defoamer.
23. The coating composition of claim 19, wherein the defoamer comprises wax and mineral oil.
24. 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.
25. The coating composition of any one of claims 1 to 21 further comprising one or more biocides.
26. 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.
27. The coating composition of any of claims 1 to 23, wherein the pigment blend further comprises precipitated synthetic silicate.
28. 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.
29. The coating composition of any one of claims 1 to 25, wherein the pigment blend further comprises a calcined extender.
30. 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.
31. The coating composition of any one of claims 1 to 30, further comprising water.
32. The coating composition of claim 31, 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.
33. A building panel comprising: a substrate having a first major surface opposite a second major surface; and a coating over the first major surface, wherein the coating comprises: a binder; and a pigment blend comprising: barium sulfate.
34. The building panel of claim 33, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
35. The building panel of any one of claims 33 or 34, wherein the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
36. The building panel of any one of claims 33 to 35, wherein a ratio of pigment-to-binder is from about 1:1 to about 20:1.
37. The building panel of any one of claims 33 to 36, 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.
38. The building panel of any one of claims 33 to 37, wherein the binder comprises vinyl acrylic polymer.
39. The building panel of any one of claims 33 to 38, wherein the pigment blend further comprises titanium dioxide, and wherein the titanium dixoide is present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
40. The building panel of any one of claims 33 to 39, wherein the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
41. The building panel of claim 40, wherein the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
42. The building panel of any one of claims 33 to 41, wherein the pigment blend further comprises one or more of: calcium carbonate; calcined diatomaceous earth; and aluminum hydroxide.
43. The building panel of any one of claims 33 to 42, wherein the pigment blend 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 composition.
44. The building panel of any one of claims 33 to 43 wherein the pigment blend 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 composition.
45. The building panel of any one of claims 33 to 44, wherein the pigment blend comprises calcium carbonate 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.
46. The building panel of any one of claims 33 to 45, further comprising a pigment extender.
47. The building panel of claim 46, wherein the pigment extender comprises barium sulfate.
48. The building panel of any one of claims 46 to 47, wherein the pigment extender is free from titanium dioxide.
49. The building panel of any one of claims 33 to 48, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, freeze-thaw additive, precipitated synthetic silicate, or other filler.
50. The building panel of any one of claims 33 to 49, wherein the building panel is a ceiling panel or a wall panel.
51. The building panel of any one of claims 33 to 50, further comprising a scrim positioned between the first major surface and the coating.
52. The building panel of claim 51, further comprising an adhesive adhering the first major surface of the substrate to the scrim.
53. The building panel of claim 52, wherein the adhesive comprises polyvinyl acetate emulsion.
54. The building panel of any one of claims 33 to 53 having an NRC value of at least about 0.5.
55. The building panel of any one of claims 33 to 54 having a CAC value of at least about 46.
56. The building panel of any one of claims 33 to 55 having a light reflectance from about 0.05 to about 0.87.
57. The building panel of any one of claims 33 to 56, wherein the coating demonstrates a hiding power of about 0.99.
58. The building panel of any one of claims 33 to 57, wherein the coating is applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2.
59. The building panel of any one of claims 33 to 58, comprising at least two coatings applied to the building panel, at least three coatings applied to the building panel, or at least four coatings applied to the building panel.
60. A surface covering system comprising: a plurality of building panels configured to be positioned adjacent to each other to form a plurality of seams between each of the plurality of building panels, each building panel comprising: a substrate having a first major surface opposite a second major surface; a seam-filling material configured to be applied to each of the plurality of seams; and a coating composition configured to be applied to the plurality of building panels and the seam-filling material, the coating composition comprising: a binder; and a pigment blend comprising: barium sulfate.
61. The surface covering system of claim 60, wherein the substrate comprises mineral fiber board, fiberglass, jute fiber, wood, or a composite material.
62. The surface covering system of any one of claims 60 to 61, wherein the substrate has an airflow resistance from about 300 mks rayls to about 700 mks rayls.
63. The surface covering system of any one of claims 60 to 62, wherein the seam-filling material comprises gypsum plaster.
64. The surface covering system of any one of claims 60 to 63, wherein a ratio of pigment-to- binder is from about 1:1 to about 20:1.
65. The surface covering system of any one of claims 60 to 64, 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.
66. The surface covering system of any one of claims 60 to 65, wherein the binder comprises vinyl acrylic polymer.
67. The surface covering system of any one of claims 60 to 66, wherein the pigment blend comprises titanium dioxide, and wherein the titanium dioxide is present at a concentration of about
0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
68. The surface covering system of any one of claims 60 to 67, wherein the barium sulfate present at a concentration of about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 8 wt. %, based upon the dry weight of the composition.
69. The surface covering system of any one of claims 67 to 68, wherein the titanium dioxide and barium sulfate are present at a ratio from about 1:1 to about 1:5.
70. The surface covering system of any one of claims 60 to 69, wherein the pigment blend further comprises one or more of: calcium carbonate; calcined diatomaceous earth; and aluminum hydroxide.
71. The surface covering system of any one of claims 60 to 70, wherein the pigment blend 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 composition.
72. The surface covering system of any one of claims 60 to 71 wherein the pigment blend 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 composition.
73. The surface covering system of any one of claims 60 to 72, wherein the pigment blend comprises calcium carbonate 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.
74. The surface covering system of any one of claims 60 to 73, further comprising a pigment extender.
75. The surface covering system of claim 74, wherein the pigment extender comprises barium sulfate.
76. The surface covering system of any one of claims 74 to 75, wherein the pigment extender is free from titanium dioxide.
77. The surface covering system of any one of claims 60 to 76, wherein the coating further comprises one or more of a defoamer, humectant, clay, wetting and dispersing additive, calcined extender, hydrophobic polymer emulsion, biocide, or precipitated synthetic silicate.
78. The surface covering system of any one of claims 60 to 77, wherein the surface covering system is a ceiling panel or a wall panel.
79. The surface covering system of any one of claims 60 to 78, wherein each building panel of the plurality of building panels comprises a scrim positioned between the first major surface and the coating.
80. The surface covering system of claim 79, further comprising an adhesive adhering the first major surface of the substrate to the scrim.
81. The surface covering system of claim 80, wherein the adhesive comprises polyvinyl acetate emulsion.
82. The surface covering system of any one of claims 60 to 81, wherein the plurality of building panels have an average NRC value of at least about 0.5.
83. The surface covering system of any one of claims 60 to 82, wherein the plurality of building panels have an average CAC value of at least about 46.
84. The surface covering system of any one of claims 60 to 83, wherein the plurality of building panels have an average light reflectance from about 0.05 to about 0.87.
85. The surface covering system of any one of claims 60 to 84, wherein the coating demonstrates a hiding power of about 0.99.
86. The surface covering system of any one of claims 60 to 85, wherein the coating is applied in an amount ranging from about 40 g/ft2 to about 60 g/ft2.
87. The surface covering system of any one of claims 60 to 86, comprising at least two coatings applied to the plurality of building panels and the seam-filling material, at least three coatings applied to the plurality of building panels and the seam-filling material, or at least four coatings applied to the plurality of building panels and the seam-filling material.
PCT/US2024/053455 2023-10-31 2024-10-29 Coating compositions for building panels Pending WO2025096468A1 (en)

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Citations (5)

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Publication number Priority date Publication date Assignee Title
US20070055012A1 (en) * 2005-08-23 2007-03-08 Caldwell Kenneth G Coating system for sag resistant formaldehyde-free fibrous panels
CN104775589B (en) * 2015-01-19 2016-05-04 广州鸿力复合材料有限公司 A kind of ceramic tile plane materiel composite plate and novel construction method thereof
US20200377741A1 (en) * 2018-01-24 2020-12-03 Coatex Composition for hard surface substrate marking
US20210171787A1 (en) * 2017-12-25 2021-06-10 Dow Global Technologies Llc Aqueous thickener blend composition
US20220073778A1 (en) * 2017-08-29 2022-03-10 Armstrong World Industries, Inc. High solids coatings for building panels

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070055012A1 (en) * 2005-08-23 2007-03-08 Caldwell Kenneth G Coating system for sag resistant formaldehyde-free fibrous panels
CN104775589B (en) * 2015-01-19 2016-05-04 广州鸿力复合材料有限公司 A kind of ceramic tile plane materiel composite plate and novel construction method thereof
US20220073778A1 (en) * 2017-08-29 2022-03-10 Armstrong World Industries, Inc. High solids coatings for building panels
US20210171787A1 (en) * 2017-12-25 2021-06-10 Dow Global Technologies Llc Aqueous thickener blend composition
US20200377741A1 (en) * 2018-01-24 2020-12-03 Coatex Composition for hard surface substrate marking

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