Mold-resistant paper and gypsum panel, antimicrobial paper coating and related methods

Abstract

A mold-resistant paper is provided. The paper is coated on at least one surface with an anti-microbial coating which includes polymerized siloxane and a fungicide. An antimicrobial paper coating and related methods are provided as well. A gypsum panel with improved resistance to mold and mildew is provided as well.

1 . A mold-resistant paper coated on at least one surface with an anti-microbial coating comprising polymerized siloxane and a fungicide. 
     
     
         2 . The mold-resistant paper of  claim 1 , wherein the fungicide is selected from the group consisting of 3-iodo-2-propynylbutyl carbamate, zinc pyrithione, zinc oxide, azoxystrobin, thiabendazol, octylisothiazoline, dichloro-octylisothiazoline, zinc dimethyldithiocarbamate, benzimidazole, 3-(3,4-dichloropheny)-1,1-dimethylurea and a combination thereof. 
     
     
         3 . The mold-resistant paper of  claim 1 , wherein the polymerized siloxane is a compound with the chemical formula [R 2 SiO] n , wherein “n” denotes a number of times the R 2 SiO unit is repeated in a polymer; and wherein each of the two R groups can be either the same or different and each R group is selected from the group consisting of a hydrogen, halogen, methyl, ethyl and phenyl. 
     
     
         4 . The mold-resistant paper of  claim 1 , wherein said paper is a multi-ply paper with at least one liner-ply and at least one filler ply. 
     
     
         5 . The mold-resistant paper of  claim 4 , wherein the liner is 100% News. 
     
     
         6 . The mold-resistant paper of  claim 4 , wherein the liner is 70% News and 30% Fly Leaf. 
     
     
         7 . The mold-resistant paper of  claim 1 , wherein the coating comprises from 1% to 10% of polymerized siloxane. 
     
     
         8 . The mold-resistant paper of  claim 1 , wherein the coating further comprises a colorant. 
     
     
         9 . The mold-resistant paper of  claim 1 , wherein the coating comprises from 1% to 10% of the fungicide. 
     
     
         10 . The mold-resistant paper of  claim 1 , wherein the fungicide is insoluble in water. 
     
     
         11 . The mold-resistant paper of  claim 1 , wherein the fungicide comprises particles and wherein at least 90% of said particles are larger than 1 micron, but smaller than 15 microns. 
     
     
         12 . The mold-resistant paper of  claim 1 , wherein the coating further comprises a binder. 
     
     
         13 . The mold-resistant paper of  claim 12 , wherein the binder is selected from the group consisting of carboxymethycellulose, polyvinyl alcohol, styrene acrylic latexes, styrene butadiene, casein and starches. 
     
     
         14 . A method of making a mold-resistant multi-ply paper, the method comprising:
 feeding the paper to a calender stack;   feeding to the calender stack an antimicrobial coating composition comprising from 1% to 10% of a non-ionic polymerized siloxane and from 1% to 10% of a water-insoluble fungicide selected from the group consisting of 3-iodo-2-propynylbutyl carbamate, zinc pyrithione, zinc oxide, azoxystrobin, thiabendazol, octylisothiazoline, dichloro-octylisothiazoline, zinc dimethyldithiocarbamate, benzimidazole, 3-(3,4-dichloropheny)-1,1-dimethylurea and a combination thereof; and   applying the antimicrobial coating composition to at least one surface of the paper with the calender stack.   
     
     
         15 . An antimicrobial coating composition, the composition comprising from 1% to 10% of a non-ionic polymerized siloxane and from 1% to 10% of a water-insoluble fungicide selected from the group consisting of 3-iodo-2-propynylbutyl carbamate, zinc pyrithione, zinc oxide, azoxystrobin, thiabendazol, octylisothiazoline, dichloro-octylisothiazoline, zinc dimethyldithiocarbamate, benzimidazole, 3-(3,4-dichloropheny)-1,1-dimethylurea and a combination thereof. 
     
     
         16 . The antimicrobial coating composition of  claim 15  further comprising a binder selected from the group consisting of carboxymethycellulose, polyvinyl alcohol, styrene acrylic latexes, styrene butadiene, casein and starches. 
     
     
         17 . A gypsum panel comprising a gypsum slurry sandwiched between two paper sheets, a front paper sheet and a back paper sheet, wherein each of the two paper sheets has a face side and a bottom side, wherein the gypsum slurry is in the proximity with the bottom sides and wherein the face sides are coated with the antimicrobial coating composition of  claim 15 . 
     
     
         18 . (canceled) 
     
     
         19 . (canceled)