Flame retardant clear coatings for building panels

Abstract

The present invention is directed to a flame-retardant building panel comprising a body having a first major surface opposite a second major surface, an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes a phosphate compound, and a metal complexing agent, wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1.

1 . A flame-retardant building panel comprising:
 a body having a first major surface opposite a second major surface;   an inorganic coating atop the first major surface, the inorganic coating comprising a flame retardant component that includes:
 a phosphate compound; and 
 a metal complexing agent; 
   wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1.   
     
     
         2 . The flame-retardant building panel according to  claim 1 , wherein the first major surface of the body is formed from a material selected from the group consisting of wood, metal, or non-woven scrim. 
     
     
         3 . The flame-retardant building panel according to  claim 1 , wherein the inorganic coating is glass-forming. 
     
     
         4 .- 5 . (canceled) 
     
     
         6 . The flame-retardant building panel according to  claim 1 , wherein the inorganic coating has a thickness ranging from about 0.5 mils to about 5.0 mils. 
     
     
         7 . The flame-retardant building panel according to  claim 1 , wherein the metal complexing agent comprises metal ion selected from the group consisting of iron, aluminum, zirconium, zinc, manganese, titanium, chromium, cobalt, and combinations thereof, and wherein the phosphate compound is selected from the group consisting of phosphoric acid, pyrophosphoric acid, polyphosphoric acid, aluminum tris (dihydrogen phosphate), sodium phosphate, potassium phosphate, and combinations thereof. 
     
     
         8 .- 12 . (canceled) 
     
     
         13 . The flame-retardant building panel according to  claim 1 , wherein the inorganic coating is optically clear. 
     
     
         14 . The flame-retardant building panel according to  claim 1 , wherein an intermediate layer is positioned between the first major surface of the body and the inorganic coating, the intermediate layer comprising an organic component wherein the organic component is selected from the group consisting of a wax emulsion, latex polymer, and combinations thereof. 
     
     
         15 . (canceled) 
     
     
         16 . The flame-retardant building panel according to  claim 1 , wherein a top coat is atop the inorganic coating, wherein the top coat is a sealant and impervious to moisture. 
     
     
         17 . (canceled) 
     
     
         18 . A flame-retardant building panel comprising:
 a body having a first major surface opposite a second major surface;   an inorganic coating applied to the first major surface, the inorganic coating formed from a composition comprising a flame retardant blend that includes:
 a phosphate compound; and 
 a metal complexing agent; 
   wherein the flame retardant blend is present in an amount ranging from about 40 wt. % to about 80 wt. % based on the total weight of the inorganic coating.   
     
     
         19 . The flame-retardant building panel according to  claim 18 , wherein the first major surface of the body is wood. 
     
     
         20 .- 21 . (canceled) 
     
     
         22 . The flame-retardant building panel according to  claim 18 , wherein the metal complexing agent comprises metal ion selected from the group consisting of iron, aluminum, zirconium, zinc, manganese, titanium, chromium, cobalt, and combinations thereof, and wherein the phosphate compound is selected from the group consisting of phosphoric acid, pyrophosphoric acid, polyphosphoric acid, aluminum tris (dihydrogen phosphate), sodium phosphate, potassium phosphate, and combinations thereof. 
     
     
         23 .- 27 . (canceled) 
     
     
         28 . The flame-retardant building panel according to  claim 18 , wherein the inorganic flame retardant coating is substantially transparent such that the first major surface of the body is visible through the inorganic coating. 
     
     
         29 . The flame-retardant building panel according to  claim 18 , wherein an intermediate layer is positioned between the first major surface of the body and the inorganic coating, the intermediate layer comprising an organic component wherein the organic component is selected from the group consisting of a wax emulsion, latex polymer, and combinations thereof. 
     
     
         30 .- 32 . (canceled) 
     
     
         33 . A flame-retardant coating composition comprising:
 a liquid carrier;   a flame-retardant blend comprising a phosphate compound and a metal complexing agent; and   wherein the phosphate compound and the metal complexing agent are present in a weight ratio ranging from about 50:1 to about 200:1.   
     
     
         34 . The flame-retardant coating composition according to  claim 33 , wherein the liquid carrier is present in an amount ranging from about 40 wt. % to about 80 wt. % based on the total weight of the coating composition. 
     
     
         35 . The flame-retardant coating composition according to  claim 33 , wherein the liquid carrier is water. 
     
     
         36 . The flame-retardant coating composition according to  claim 33 , wherein the phosphate compound is selected from the group consisting of phosphoric acid, pyrophosphoric acid, polyphosphoric acid, aluminum tris (dihydrogen phosphate), sodium phosphate, potassium phosphate, and combinations thereof. 
     
     
         37 . The flame-retardant coating composition according to  claim 33 , wherein the metal complexing agent comprises metal ion selected from the group consisting of iron, aluminum, zirconium, zinc, manganese, titanium, chromium, cobalt, and combinations thereof, wherein the metal ion is iron and a weight ratio of the phosphate compound to the metal ion is at least about 20,000:1. 
     
     
         38 . (canceled) 
     
     
         39 . The flame-retardant coating composition according to  claim 33 , wherein the inorganic coating further comprises a filler is selected from the group consisting of calcium carbonate, aluminum carbonate, lithium carbonate, magnesium carbonate, silica, fumed silica, and combinations thereof. 
     
     
         40 . The flame-retardant coating composition according to  claim 33 , wherein the flame retardant blend is present in an amount of 25 wt. % to about 60 wt. % based on the total weight of the flame-retardant coating composition. 
     
     
         51 .- 75 . (canceled)