Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING 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
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/60—Additives non-macromolecular
  • C09D7/61—Additives non-macromolecular inorganic
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING 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
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/02—Emulsion paints including aerosols
  • C09D5/024—Emulsion paints including aerosols characterised by the additives
  • C09D5/028—Pigments; Filters
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING 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
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/04—Thixotropic paints
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING 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
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/66—Additives characterised by particle size
  • C09D7/69—Particle size larger than 1000 nm
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING 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
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/70—Additives characterised by shape, e.g. fibres, flakes or microspheres
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
  • E04B1/84—Sound-absorbing elements
  • E04B1/8409—Sound-absorbing elements sheet-shaped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/20—Oxides; Hydroxides
  • C08K3/22—Oxides; Hydroxides of metals
  • C08K2003/2237—Oxides; Hydroxides of metals of titanium
  • C08K2003/2241—Titanium dioxide
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/24—Acids; Salts thereof
  • C08K3/26—Carbonates; Bicarbonates
  • C08K2003/265—Calcium, strontium or barium carbonate
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/002—Physical properties
  • C08K2201/005—Additives being defined by their particle size in general
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/20—Oxides; Hydroxides
  • C08K3/22—Oxides; Hydroxides of metals
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/24—Acids; Salts thereof
  • C08K3/26—Carbonates; Bicarbonates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/346—Clay
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/36—Silica
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/22—Expanded, porous or hollow particles
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/22—Expanded, porous or hollow particles
  • C08K7/24—Expanded, porous or hollow particles inorganic
  • C08K7/28—Glass
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
  • E04B9/045—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being laminated
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
  • E04B9/065—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising supporting beams having a folded cross-section
  • E04B9/067—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising supporting beams having a folded cross-section with inverted T-shaped cross-section
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
  • E04B9/12—Connections between non-parallel members of the supporting construction
  • E04B9/127—Connections between non-parallel members of the supporting construction one member being discontinuous and abutting against the other member
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/22—Connection of slabs, panels, sheets or the like to the supporting construction
  • E04B9/24—Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto
  • E04B9/245—Connection of slabs, panels, sheets or the like to the supporting construction with the slabs, panels, sheets or the like positioned on the upperside of, or held against the underside of the horizontal flanges of the supporting construction or accessory means connected thereto by means of screws, bolts or clamping strips held against the underside of the supporting construction
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
  • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster

Definitions

• the invention relates to acoustically transparent coatings useful for improving the appearance of
• U.S. Patents 8,684,134, 8,770,345 and 8,925,677 disclose drywall sheets or panels used to construct monolithic acoustical ceilings. The panels are
• the invention provides a finish or appearance coating for an acoustical substrate that is characterized by a high porosity with a resulting high acoustical transparency and that can be efficiently sanded for a smooth, uniform appearance.
• the coating is particularly useful for concealing the perforations in drywall sheets clad with a translucent or semi-transparent non-woven veil and taped joints between such sheets in a monolithic acoustical ceiling construction.
• the disclosed coating material is adapted to be sprayed in droplet form in multiple layers that are allowed to dry before a successive layer is applied.
• the resulting coating structure is a three dimensional matrix of residual droplets and intervening voids or pores.
• the coating material is characterized by relatively large filler particles, notably high pigment volume
• the coating material is sprayed in a form of relatively large droplets. Owing to the physical properties of the material, the droplets retain at least some of their individual character once deposited on the substrate or the previous layer of the material. The droplets, due to their viscosity and quick drying
• the droplets retain sufficient individuality to provide open spaces between the droplets of the same coating layer as well as the previous coating layer.
• the open spaces which are small enough to be overlooked by the unaided eyes of a casual observer in a ceiling
• interconnect through the separate coat layers providing a porosity through the entire thickness of the coating.
• the disclosed coating formula besides affording acoustical transparency, can be readily sanded to provide a relatively smooth appearance.
• FIG. 1 is a fragmentary, schematic, isometric view of a gypsum panel acoustical monolithic ceiling employing the invention
• FIG. 2 is a fragmentary, cross-sectional view on an enlarged scale of the monolithic acoustical ceiling of FIG. 1;
• FIG. 3 is a scanning electron microphotograph representing a face of the inventive coating
• FIG. 4 is a generalized graph of the viscosity of a formula of the inventive coating
• FIG. 5 is a graph of typical air flow resistivity of the inventive coating.
• FIG. 6 is a photograph showing the outer layer of the inventive coating as first dried on the right and after sanding on the left.
• FIG. 1 there is shown a schematic partial view of an acoustical monolithic ceiling
• the ceiling 10 is a suspended system including a drywall grid
• a perimeter of the grid 11 is conventionally formed by channel molding 15 secured to respective walls 16.
• Acoustical panels 20 are attached to the lower sides of the grid tees 12, 13 with self-drilling screws 21.
• the illustrated acoustical panels are 4 ft. by 8 ft. in their planar dimensions, but can be longer, shorter and/or of different width as desired or practical.
• the size of the panel 20 and spacing of the grid tees 12 and 13, allows the edges of the panel to underlie and be directly attached to a grid tee, assuring that these edges are well supported.
• the acoustical panel 20 is characterized with a perforated gypsum core 24.
• One method of providing the core 24 is to modify a standard commercially available sheet of drywall by perforating it through a front paper face 23, the gypsum core 24, and a rear paper side or face 25.
• Perforations 28 can be formed by drilling, punching, or with other known hole- making techniques.
• the perforations 28 are preferably uniformly spaced; by way of an example, the perforations can be round holes of 8 mm diameter on 16 mm centers. This arrangement produces a total area of the
• perforations substantially equal to 20% of the full planar area of a panel 20.
• Other hole sizes, shapes, patterns and densities can be used. For example, tests have shown that a hole density of 9% of the total area can achieve good results.
• Marginal areas, as well as intermediate areas corresponding to centers of support grid, joists, or studs, of a sheet can be left
• Sheets 29, 30 are laminated to both full sides of the perforated drywall sheet thereby at least partially closing both ends of the perforations 28.
• the backer sheet or web 30 is preferably an acoustically absorbent non-woven fabric known in the acoustical ceiling panel art.
• the backer fabric can be that marketed under the trademark SOUNDTEX® by Freudenberg Vliesstoffe KG.
• a sheet or web in the form of a non-woven fabric scrim layer 29 is attached with a suitable adhesive.
• the facing layer or sheet 29 is porous; a suitable material for this
• the panel 20 with other identical panels is hung on the grid 11 in the same manner as ordinary drywall is installed. Similarly, as shown in FIG. 1, joints 33 are taped in the same way as regular drywall is taped.
• Drywall joint compound or similar material 34 is used to adhere a tape or similar material 35 to adjacent margins of two abutting panels 20 by applying it directly to the sheets 29 and over the tape 35 to conceal the tape.
• the front sheets 29 and remaining joint compound are painted with an acoustically transparent coating 31 of the invention.
• monolithic it is to denote that essentially the entire visible surface of a ceiling or wall appears to be a seamless expanse without joints.
• the coating 31, in accordance with the invention, is sprayed onto the room facing side of the panels 20 clad with the scrim or veil 29 which constitute a substrate for the coating.
• the coating 31, ideally, has several physical properties including relatively large filler particles, notably high pigment volume concentration (PVC) , high viscosity, shear thinning, and fast drying performance. When used as an appearance coat for ceiling structures, the coating 31 should dry white.
• a formulation for a suitable coating includes a binder and relatively large particles serving as a pigment or filler of a size larger than that ordinarily used in conventional paint-like coatings.
• the binder can be a resin or polymer binder in or useable as an aqueous dispersion such as, but not limited to, acrylic, styrene, or vinyl polymer latex or oil-based media such as an alkyd, polyurethane, polyester, or epoxy and combinations thereof .
• the relatively large particles include, but are not limited to, glass spheres, perlite, ceramic, fly ash, polymeric spheres, borosilicate, coarse sand, silica, and coarse carbonate.
• the relatively large particles are spherical or three-dimensional in shape without a
• the size of the large particles can range between 20 and 900 microns.
• Table 1 below sets out an example of a suitable formula for the inventive acoustically transparent sandable coating 31.
• the function or role of the various constituents is noted in the column on the far right. Water, thickener, binder and large particle filler are essential and the biocide is essential while the formula resides in a can. The remaining constituents can be considered optional.
• the titanium dioxide has an average particle size of about 0.6 microns; the calcium carbonate can have an average particle size of about 12 microns, and the plate-like mica can have major
• the 3M Kl material is glass bubbles (hollow spheres) of soda-lime borosilicate with a reported true density of typically 0.125 grams/cc. and an average particle size of 65 microns.
• the 3M Kl material is particularly useful in practice of the invention. This material occupies much of the volume of the formulation owing to its relatively low density resulting from its hollow sphere structure.
• the Kl material additionally, has a relatively low oil absorption of 0.2 - 0.6 grams oil/cc of product per ASTM D281-84. Still further, the Kl material has a natural white color which is useful in ceiling applications.
• the titanium dioxide serves as an opacity improving filler and whitening pigment.
• the calcium carbonate increases the solids and density of the coating to further improve drying time and hardness of the dried coating.
• the pigment volume concentration (PVC) of the coating formulation is the pigment volume concentration (PVC) of the coating formulation, based on all the solids.
• the ratio of the volume of relatively large particle fillers to fillers of more conventional lesser size can range between about 0.1 to about 10.
• the coating formulation of Table 1 has a relatively high viscosity of about 190 BBU (Brabender Units) to about 265 BBU at room temperature.
• formulations can have a viscosity of between about 66 BBU to about 1450 BBU at room temperature.
• Table 1 formulation characteristics of the Table 1 formulation is generalized in FIG. 4 where by the measured viscosity drops more than 40:1.
• the viscosity in part, is contributed by the thickener component of the formulation.
• the listed thickener is cellulosic, but known synthetic and natural thickeners can be used.
• the thickener also serves to keep the constituents in suspension.
• the generalized viscosity chart of FIG. 4 was measured on a Brookfield HA viscometer using a T-bar:C spindle.
• Alternative coating formulations should have a high shear thinning property so that the viscosity can reduce by a factor of at least 10 to 1 under shear conditions.
• the wet coating material is sprayed in large droplets using, for example, a conventional hopper texture sprayer such as that marketed by Graco .
• the gun and/or its air supply is adjusted so that the droplets are about 1 to about 4 mm. in size and,
• the shear thinning property, characterized in FIG. 4, of the wet coating allows it to be readily sprayed in droplet form despite its high viscosity.
• a single coating layer should involve spraying the substrate in two perpendicular directions or passes so that a uniform covering by the layer is achieved. Two to seven layers can be applied, with four layers being preferred, to conceal the
• Coverage by the total coating layers can be between 15 to 35 square foot per gallon, with 25 square foot being
• the formulation of Table 1 or a like formulation has a density of 4 to 11 lbs. per gallon with a preferred range of 5 to 6.5 lbs. per gallon.
• FIG. 3 demonstrates the porous nature of the
• inventive coating when applied to an acoustical
• FIG. 3 shows that the droplets retain an individual nature while the binder bonds the solids to the substrate at the first layer and to
• the scale on the lower right-hand corner of FIG. 3 indicates a measure of 1 mm. and droplets can be observed in the FIG. measuring more or less than 1 mm.
• the dried droplets range between 1/2 and 2-1/2 mm. The original droplet size will shrink when the water content
• Voids dark areas in FIG. 3, can be observed between the residual droplet forms. These voids are interconnected through the thickness of the coating resulting in a porous and acoustically transparent coating. Voids or pores in FIG. 3 are generally less than 0.5 mm in size so that at ceiling height they are not readily observable by a person standing on the associated floor. The low
• the combination of high viscosity and fast drying properties enables the droplets to beneficially retain their individuality and avoid completely merging with adjacent droplets.
• the disclosed formulation of Table 1 applied in the specified layers dries to the extent that it will not transfer to a finger, i.e. is dry to the touch, most preferably after 20 minutes for a first coat and 30 minutes on subsequent coats in an environment of 75 degrees F. and 50% relative humidity.
• alternative formulations with fast drying properties will dry to the touch in 60 minutes in a first coat. This fast drying property of the coating is also important since it enables a painter to complete a job on the same day .
• FIG. 5 illustrates typical airflow resistivity as measured separately for each successive dry coat of the Table 1 material.
• the resistivity is determined with an air flow of 2 liters per minute through a surface area of 3.14 square inches.
• the total dry thickness of the coating tested in FIG. 5 was 0.031 inch.
• the initial resistivity reading at "0 coats" is a measure of the resistivity of the veil 29.
• the dry coating is
• FIG. 6 illustrates the sprayed and dried finish of the top (outer) layer of the inventive coating.
• Architects, interior designers, building owners and/or tenants may prefer a smoother finish.
• a finer texture shown at the left in FIG. 6 can be obtained with the inventive coating formulation, without loss of acoustical transparency, by a sanding process.
• the inventive coating, as a result of the notably high pigment volume concentration formulation can be readily sanded while retaining acoustical
• the coating surface is characterized by macroscopic hills and valleys corresponding to
• the inventive coating is characterized with a major part of its surface area being essentially flat, ignoring very fine sandpaper scratch marks, and
• a ceiling area of 400 square foot covered with the inventive coating can be manually sanded with a pole sander in 45 minutes to obtain a flat surface represented at the left in FIG. 6. This can be compared for reference to another formulation requiring as much as 1 hour and 45 minutes to manually sand a 400 square foot ceiling area. Dust particles not removed in the sanding process can be removed with an air blower, jet, or vacuum, for example.
• Sanding tests were conducted to objectively measure the sandability of the inventive coating requiring 45 minutes and the reference coating requiring 1 hour and 45 minutes of manual sanding of a 400 square foot ceiling area. The tests were conducted according to the ASTM D2486 standard (Test Method A) with appropriate

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Wood Science & Technology (AREA)
• Life Sciences & Earth Sciences (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Architecture (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Acoustics & Sound (AREA)
• Nanotechnology (AREA)
• Dispersion Chemistry (AREA)
• Mechanical Engineering (AREA)
• Inorganic Chemistry (AREA)
• Paints Or Removers (AREA)
• Building Environments (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

Priority Applications (8)

Applications Claiming Priority (2)

Publications (1)

Family

ID=63638314

Family Applications (1)

Country Status (10)

Families Citing this family (1)

Citations (8)

Family Cites Families (5)

• 2017
  • 2017-08-15 US US15/677,345 patent/US10316201B2/en active Active
• 2018
  • 2018-08-14 CN CN201880051538.1A patent/CN110997826A/zh active Pending
  • 2018-08-14 KR KR1020207006295A patent/KR102382455B1/ko active Active
  • 2018-08-14 WO PCT/US2018/046638 patent/WO2019036434A1/en not_active Ceased
  • 2018-08-14 MX MX2020001478A patent/MX2020001478A/es unknown
  • 2018-08-14 PL PL18772959.5T patent/PL3668930T3/pl unknown
  • 2018-08-14 EP EP18772959.5A patent/EP3668930B1/en active Active
  • 2018-08-14 CA CA3072590A patent/CA3072590C/en active Active
  • 2018-08-14 JP JP2020506779A patent/JP6979511B2/ja active Active
  • 2018-08-14 AU AU2018317387A patent/AU2018317387B2/en active Active
• 2019
  • 2019-05-22 US US16/419,345 patent/US10590288B2/en active Active

Patent Citations (9)

Also Published As

Similar Documents

Legal Events