	US 12,281,238 B2
	Sag resistant, formaldehyde-free coated fibrous substrate
Lida Lu, Coraopolis, PA (US); and Kenneth G. Caldwell, Mountville, PA (US)
Assigned to AWI Licensing LLC, Wilmington, DE (US)
Filed by ARMSTRONG WORLD INDUSTRIES, INC., Lancaster, PA (US)
Filed on Apr. 18, 2023, as Appl. No. 18/136,068.
Application 18/136,068 is a continuation of application No. 16/031,025, filed on Jul. 10, 2018, granted, now 11,634,591.
Application 16/031,025 is a continuation of application No. 12/970,011, filed on Dec. 16, 2010, granted, now 10,017,648, issued on Jul. 10, 2018.
Prior Publication US 2023/0250297 A1, Aug. 10, 2023
Int. Cl. C09D 5/02 (2006.01); C09D 7/63 (2018.01); C09D 133/02 (2006.01); E04C 2/16 (2006.01); E04C 2/24 (2006.01); C08K 5/053 (2006.01); C09D 125/08 (2006.01)

CPC C09D 5/024 (2013.01) [C09D 7/63 (2018.01); C09D 133/02 (2013.01); E04C 2/16 (2013.01); E04C 2/246 (2013.01); C08K 5/053 (2013.01); C09D 125/08 (2013.01); Y10T 428/251 (2015.01); Y10T 428/31507 (2015.04); Y10T 428/31739 (2015.04); Y10T 428/31786 (2015.04); Y10T 428/31931 (2015.04); Y10T 428/31935 (2015.04); Y10T 428/31971 (2015.04)]

19 Claims

1. A method of manufacture of a sag-resistant building panel comprising

applying a coating composition to a major surface of a substrate, the coating composition comprising:

a polymeric binder comprising polyacrylic acid;

a polyol crosslinker selected from the group consisting of diethanolamine, triethanolamine, glycerol, dextrose, sucrose, fructose, sorbitol, and combinations thereof;

a neutralizing agent;

liquid carrier; and

a filler, wherein the filler and polymeric binder are present at a weight ratio ranging from about 2:1 to about 6:1;

wherein the coating composition is formaldehyde-free and has a pH of at least 8; and

drying the coating composition applied to the substrate such that the liquid carrier is evaporated to form the sag-resistant building panel.