Stain resistant acoustical panels

Abstract

Disclosed is a stain resistant acoustical panel. The panel may incorporate within its structure a relatively small quantity of latex which forms an ultra thin coating within the panel such that water may pass through the inner structure of the panel. Furthermore, the panel may have a coating or primer applied to the facing side of the panel to prevent water stains. The coating contains a chelating agent which provides stain resistance to the coated face of the panel. Additionally, the panel may incorporate both latex within its structure and a primer coating comprising a chelating agent.

1 . A stain resistant acoustical panel comprising: 
 a first major surface and an opposing second major surface; and    at least one of the major surfaces having a coating including a chelating agent.    
     
     
         2 . The stain resistant acoustical panel of  claim 1 , wherein the coating further comprises a binder and a filler.  
     
     
         3 . The stain resistant acoustical panel of  claim 2 , wherein the coating comprises on a dry weight percent basis of between about 1.5% to about 35% binder.  
     
     
         4 . The stain resistant acoustical panel of  claim 2 , wherein the binder is hydrophilic.  
     
     
         5 . The stain resistant acoustical panel of  claim 4 , wherein the binder is selected from the group consisting of starch, polyamides, polyacrylamides, polymethacrylamides, proteins, polyvinyl alcohol, latex, polyureas and mixtures thereof.  
     
     
         6 . The stain resistant acoustical panel of  claim 2 , wherein the coating comprises on a dry weight percent basis of between about 35% to about 99% filler.  
     
     
         7 . The stain resistant acoustical panel of  claim 2 , wherein the filler is selected from the group consisting of calcium carbonate, talc, perlite, dolomite, sand, barium sulfate, mica, silica, gypsum, wollastonite, calcite, aluminum trihydrate, zinc oxide, zinc sulfate, solid polymer particles, hollow beads and mixtures thereof.  
     
     
         8 . The stain resistant acoustical panel of  claim 1 , wherein the coating comprises on a dry weight percent basis of between about 0.1% to about 25% of chelating agents.  
     
     
         9 . The stain resistant acoustical panel of  claim 1 , wherein the chelating agent comprises a metal oxide.  
     
     
         10 . The stain resistant acoustical panel of  claim 9 , wherein the metal oxide is selected from the group consisting of zinc oxide, aluminum oxide, zirconium oxide and combinations thereof.  
     
     
         11 . The stain resistant acoustical panel of  claim 1 , wherein the chelating agent is selected from the group consisting of soluble zirconium, aluminum, zinc and combinations thereof.  
     
     
         12 . A stain resistant acoustical panel comprising: 
 fibers;    starch; and    a latex wherein the ratio of latex to starch on dry weight percent basis is between about 1 to 330 and about 1 to 4.1.    
     
     
         13 . The stain resistant acoustical panel of  claim 12 , wherein the latex further comprises a functional group selected from the group consisting of carboxylic acid, methylol, hydroxyl, urethane, amide, urea and combinations thereof.  
     
     
         14 . The stain resistant acoustical panel of  claim 13 , wherein carboxylic acid comprises from about 0.02% to about 7% by weight of the latex.  
     
     
         15 . The stain resistant acoustical panel of  claim 12 , wherein the ratio of latex to starch on a dry weight percent basis is between about 1 to 49 and about 1 to 4.5.  
     
     
         16 . A stain resistant acoustical panel comprising: 
 fibers;    starch;    a latex wherein the ratio of latex to starch on dry weight percent basis is between about 1 to 330 and about 1 to 4.1; and    a coating including a chelating agent applied to a facing side of the panel.    
     
     
         17 . The stain resistant acoustical panel of  claim 16 , wherein the coating further comprises a binder and a filler.  
     
     
         18 . The stain resistant acoustical panel of  claim 16 , wherein the latex further comprises a functional group selected from the group consisting of carboxylic acid, methylol, hydroxyl, urethane, amide, urea and combinations thereof.  
     
     
         19 . The stain resistant acoustical panel of  claim 18 , wherein carboxylic acid comprises from about 0.02% to about 7% by weight of the latex.  
     
     
         20 . The stain resistant acoustical panel of  claim 18 , wherein the ratio of latex to starch on a dry weight percent basis is between about 1 to 49 and about 1 to 4.5.