U.S. patent application number 13/490595 was filed with the patent office on 2013-01-24 for use of aldehyde scavengers in interior building products.
This patent application is currently assigned to USG INTERIORS, LLC. The applicant listed for this patent is Salvatore Immordino, Runhai Lu, Terry L. Rosenstiel, Weixin D. Song. Invention is credited to Salvatore Immordino, Runhai Lu, Terry L. Rosenstiel, Weixin D. Song.
Application Number | 20130023612 13/490595 |
Document ID | / |
Family ID | 47556203 |
Filed Date | 2013-01-24 |
United States Patent
Application |
20130023612 |
Kind Code |
A1 |
Lu; Runhai ; et al. |
January 24, 2013 |
USE OF ALDEHYDE SCAVENGERS IN INTERIOR BUILDING PRODUCTS
Abstract
A coating for application to the surface of an interior building
product comprises: a resin formulation such as a melamine
formaldehyde resin characterized by its ability to strengthen the
interior building product when applied as a coating to the building
product; and an aldehyde scavenger selected from the group
consisting of; tetraethylene pentamine, propionamide, caprolactam,
ammonium hydroxide, sodium bisulfate, sodium metabisulfite,
ammonium primary phosphate, ammonium secondary phosphate, a
combination of ammonium primary phosphate and ammonium secondary
phosphate, a combination of ammonium primary phosphate, ammonium
secondary phosphate and a sulfite, a polyvinyl alcohol; adipic
dihydrazide and a combination of a polyvinyl alcohol and adipic
dihydrazide.
Inventors: |
Lu; Runhai; (Vernon Hills,
IL) ; Rosenstiel; Terry L.; (Vernon Hills, IL)
; Immordino; Salvatore; (Trevor, WI) ; Song;
Weixin D.; (Vernon Hills, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lu; Runhai
Rosenstiel; Terry L.
Immordino; Salvatore
Song; Weixin D. |
Vernon Hills
Vernon Hills
Trevor
Vernon Hills |
IL
IL
WI
IL |
US
US
US
US |
|
|
Assignee: |
USG INTERIORS, LLC
Chicago
IL
|
Family ID: |
47556203 |
Appl. No.: |
13/490595 |
Filed: |
June 7, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61510109 |
Jul 21, 2011 |
|
|
|
Current U.S.
Class: |
524/192 ;
524/425; 524/503 |
Current CPC
Class: |
C09D 161/28 20130101;
C09D 7/63 20180101; C09D 7/00 20130101; C09D 161/00 20130101; C09D
7/65 20180101; C09D 161/28 20130101; C08K 3/26 20130101; C08L 29/04
20130101; C09D 161/28 20130101; C08K 2003/265 20130101; C08L 29/04
20130101 |
Class at
Publication: |
524/192 ;
524/503; 524/425 |
International
Class: |
C09D 161/28 20060101
C09D161/28; C08K 5/29 20060101 C08K005/29; C08K 3/26 20060101
C08K003/26; C09D 129/04 20060101 C09D129/04 |
Claims
1. A coating for application to the surface of an interior building
product comprising: a resin formulation characterized by its
ability to strengthen the interior building product when applied as
a coating to the building product; and an aldehyde scavenger
selected from the group consisting of; tetraethylene pentamine,
propionamide, caprolactam, ammonium hydroxide, sodium bisulfate,
sodium metabisulfite, ammonium primary phosphate, ammonium
secondary phosphate, a combination of ammonium primary phosphate
and ammonium secondary phosphate, a combination of ammonium primary
phosphate, ammonium secondary phosphate and a sulfite, a polyvinyl
alcohol; adipic dihydrazide and a combination of a polyvinyl
alcohol and adipic dihydrazide.
2. The coating of claim 1 wherein the interior building product
comprises ceiling tile.
3. The coating of claim 1 wherein the resin formulation includes a
melamine formaldehyde resin.
4. The coating of claim 3 wherein the aldehyde scavenger comprises
a polyvinyl alcohol.
5. The coating of claim 4 wherein the polyvinyl alcohol comprises a
polyvinyl alcohol having a CAS Number of 25213-24-5.
6. The coating of claim 5 wherein the interior building product
comprises ceiling tile.
7. The coating of claim 1 wherein the aldehyde scavenger comprises
adipic dihydrazide.
8. The coating of claim 7 wherein the interior building product
comprises ceiling tile.
9. The coating of claim 3 wherein the melamine formaldehyde resin
formulation comprises by weight: approximately 10% to 20% of a
melamine formaldehyde resin; approximately 20% to 60% of a calcium
carbonate filler and approximately 0% to 10% of a clay filler;
approximately 20% to 80% water; a catalyst selected from the group
consisting of; ammonium chloride, magnesium chloride and a
combination of ammonium chloride and magnesium chloride; and
sufficient defoamer to suppress the formation of any foam in the
resin formulation.
10. The coating of claim 9 wherein the melamine formaldehyde resin
formulation comprises by weight: approximately 10% to 20% of a
melamine formaldehyde resin; approximately 35% of a calcium
carbonate filler and approximately 5% of a clay filler; and
approximately 40% water;
11. The coating of claim 10 wherein the aldehyde scavenger
comprises a polyvinyl alcohol.
12. The coating of claim 11 wherein the polyvinyl alcohol comprises
a polyvinyl alcohol having a CAS Number of 25213-24-5.
13. The coating of claim 12 wherein the interior building product
comprises ceiling tile.
14. The coating of claim 10 wherein the aldehyde scavenger
comprises adipic dihydrazide.
15. The coating of claim 14 wherein the interior building product
comprises ceiling tile.
16. The coating of claim 10 wherein the aldehyde scavenger
comprises a combination of a polyvinyl alcohol and adipic
dihydrazide.
17. The coating of claim 16 wherein the interior building product
comprises ceiling tile.
18. The coating of claim 17 wherein the polyvinyl alcohol comprises
a polyvinyl alcohol having a CAS Number of 25213-24-5.
19. The coating of claim 18 wherein the interior building product
comprises ceiling tile.
Description
[0001] This application claims the benefit of U.S. provisional
patent application Ser. No. 61/510,109, filed Jul. 21, 2011.
FIELD OF THE INVENTION
[0002] The present invention in general concerns coatings that are
applied to interior building products, such as ceiling tile for
example, wherein the coatings include an aldehyde scavenger that
possesses the ability to tie-up any aldehydes, including
formaldehyde, and/or other volatile organic compounds that may tend
to be emitted from the basic interior building products themselves
and/or the coatings.
BACKGROUND OF THE INVENTION
[0003] Many interior building products such as ceiling tiles, fiber
panels and gypsum wallboard and other types of wallboard, for
example, following their installation, can exhibit a tendency to
emit aldehyde, including formaldehyde, vapors and/or other kinds of
volatile organic compounds ("VOCs") to their surroundings. The
sources of the aldehydes and other VOC's may reside in the basic
interior building product itself or in coverings, coatings and
other adjuncts applied to the basic interior building product.
[0004] The emission of the aldehydes and other VOCs can be
undesirable and efforts can be undertaken to avoid their release
into their surroundings because of their deleterious effects on
human and animal health, as well as on the general comfort of
humans and animals exposed to the emissions. In this regard,
formaldehyde and certain other VOC's that can be emitted from
interior building products have been classified as cancer-causing
agents.
[0005] Therefore, a need exists to control the emission of
aldehydes, including formaldehyde, and other VOC's from these
interior building products. One method of doing so involves
incorporating with the interior building products a substance that
will tie-up the aldehydes and other VOC's and prevent them from
being released from the interior building products into the
surrounding environment. Such substances can be incorporated into
the interior building products either when the interior building
products are manufactured, at the time the interior building
products are installed or after the interior building products are
installed for example.
[0006] One consideration in determining the suitability of any
particular substance for the purpose of tying-up aldehydes and
other VOC's can be the effect the composite that is formed as a
result of the substance tying-up an aldehyde or another VOC has on
the interior building product. That is to say that the composite
should not adversely affect the physical or chemical properties or
esthetic values of the interior building product.
SUMMARY OF THE INVENTION
[0007] As used herein the expression "aldehyde scavenger" is
intended to refer to any substance used for the purpose of tying-up
aldehydes and other VOC's whether, for example, by covalent
chemical bonding, ionic interaction, improved incorporation of the
aldehydes and/or other VOC's to the substrate at which the
aldehydes and/or other VOC's are present, phase transformation,
hydrogen bonding or otherwise.
[0008] According to one aspect, the present invention concerns a
coating for application to the surface of an interior building
product, including a resin formulation characterized by its ability
to strengthen the interior building product when applied as a
coating to the building product together with an aldehyde
scavenger.
[0009] According to another aspect of the invention, the aldehyde
scavenger is selected from the group consisting of; tetraethylene
pentamine, propionamide, caprolactam, ammonium hydroxide, sodium
bisulfate, sodium metabisulfite, ammonium primary phosphate,
ammonium secondary phosphate, a combination of ammonium primary
phosphate and ammonium secondary phosphate, a combination of
ammonium primary phosphate, ammonium secondary phosphate and a
sulfite, a polyvinyl alcohol, adipic dihydrazide and a combination
of a polyvinyl alcohol and adipic dihydrazide.
[0010] In a further aspect of the invention, the resin formulation
includes a melamine formaldehyde resin and the aldehyde scavenger
comprises individually, or in combination, a polyvinyl alcohol and
adipic dihydrazide.
[0011] In an additional aspect of the invention, the melamine
formaldehyde resin formulation comprises by weight: approximately
10% to 20% of a melamine formaldehyde resin; approximately 20% to
60% of a calcium carbonate filler and approximately 0% to 10% of a
clay filler; approximately 20% to 80% water; an ammonium chloride
and/or magnesium catalyst; and sufficient defoamer to suppress the
formation of any foam in the resin formulation. In a particular
embodiment of this additional aspect, the melamine formaldehyde
resin formulation comprises by weight: approximately 10% to 20% of
a melamine formaldehyde resin; approximately 35% of a calcium
carbonate filler and approximately 5% of a clay filler; and
approximately 40% water.
[0012] In yet another aspect of the invention, the interior
building product to which the coating is applied can comprise
ceiling tile.
DETAILED DESCRIPTIONS OF EXAMPLES OF THE INVENTION
[0013] Examples of embodiments that incorporate one or more aspects
of the present invention are described below. These examples are
not intended to be limitations on the present invention. Thus, for
example, in some instances, one or more examples of the present
invention described with reference to one aspect or embodiment can
be utilized in other aspects and embodiments. In addition, certain
terminology is used herein for convenience only and is not to be
taken as limiting the present invention.
[0014] The present invention has application to a variety of
interior building products including, for example, ceiling tiles,
fiber panels and gypsum wallboard and other types of wallboard and
comprises coatings that are applied to at least one surface of the
interior building products. In a particular employment of the
invention, the coating is applied to the back of a ceiling tile;
that is, the surface of the ceiling tile that is not exposed. In an
embodiment of the invention, the coatings include a resin
formulation characterized by its ability to strengthen the interior
building products when applied as a coating to the building
products together with an aldehyde scavenger. The coatings can be
applied to the surface of the ceiling tiles by employing spraying
techniques or rollers that hold the coatings, for example, and can
be applied at the completion of the tile-manufacturing process, at
the time the ceiling tiles are installed or following the
installation of the ceiling tiles for example.
[0015] In an embodiment of the invention, the resin formulation
includes a melamine formaldehyde resin such as, for example, a
butylated form of the resin that is dissolved in n-butanol and
xylene and then cross-linked with alkyd, epoxy, acrylic and
polyester resins. The melamine formaldehyde resin forms a hard
covering on the ceiling tile and provides the ceiling tile with the
strength required for the ceiling tile to remain intact while being
suspended from open gridwork typically installed at the ceilings of
interior structures for example.
[0016] In a particular aspect of the present invention, the
melamine formaldehyde resin can be included in a melamine
formaldehyde resin formulation included in the coatings of the
invention comprising by weight: approximately 10% to 20% of the
melamine formaldehyde resin; approximately 20% to 60% of a calcium
carbonate filler and approximately 0% to 10% of a clay filler;
approximately 20% to 80% water; an effective amount of an ammonium
chloride and/or magnesium chloride catalyst; and sufficient
defoamer to suppress the formation of any foam in the resin
formulation. In an embodiment of this particular aspect of the
invention, the melamine formaldehyde resin can be included in a
melamine formaldehyde resin formulation comprising by weight:
approximately 10% to 20% of a melamine formaldehyde resin;
approximately 35% of a calcium carbonate filler and approximately
5% of a clay filler; and approximately 40% water.
[0017] In addition to the resin formulation, the coatings of the
present invention include an aldehyde scavenger. The primary
function of the aldehyde scavenger is to tie-up any aldehydes and
other VOC 's that may tend be emitted from the ceiling tiles
themselves and/or coatings applied to the ceiling tiles and prevent
such aldehydes and other VOC 's from being emitted into the
surroundings where the ceiling tiles have been installed. The
tying-up of any aldehydes and other VOC's can occur, for example,
as a result of covalent chemical bonding, ionic interaction,
improved incorporation of the aldehydes and/or other VOC 's to the
ceiling tiles at which the aldehydes and/or other VOC's are
present, phase transformation, hydrogen bonding or otherwise. When
a formaldehyde resin formulation is employed in the coatings,
typically the emission of aldehydes will arise from that
formulation. However, the aldehydes and any other VOC's that may
tend to be emitted can arise from any of the components that go
into the manufacture of the ceiling tile. The coatings, including
the aldehyde scavenger, can be applied to the ceiling tiles either
when the ceiling tiles are manufactured, at the time the ceiling
tiles are installed or after the ceiling tiles are installed.
[0018] In accordance with one aspect of the invention, the aldehyde
scavenger can comprise a scavenger selected from the group
consisting of; tetraethylene pentamine, propionamide, caprolactam,
ammonium hydroxide, sodium bisulfate, sodium metabisulfite,
ammonium primary phosphate, ammonium secondary phosphate, a
combination of ammonium primary phosphate and ammonium secondary
phosphate, a combination of ammonium primary phosphate, ammonium
secondary phosphate and a sulfite, a polyvinyl alcohol, adipic
dihydrazide and a combination of a polyvinyl alcohol and adipic
dihydrazide. In particular embodiments of the present invention,
the aldehyde scavenger can comprise a polyvinyl alcohol such as
Celvol.RTM. 205S or Celvol.RTM. 203S having a Chemical Abstracts
Service registry number ("CAS Number") of 25213-24-5, adipic
dihydrazide, and a combination of a polyvinyl alcohol such as
Celvol.RTM. 205S or Celvol.RTM. 203S having a Chemical Abstracts
Service registry number ("CAS Number") of 25213-24-5 and adipic
dihydrazide.
[0019] While the present invention has been described above and
illustrated with reference to certain embodiments thereof, it is to
be understood that the invention is not so limited. In addition,
modifications and alterations of the aspects of the invention
described herein will occur to those skilled in the art upon
reading and understanding the specification, including the
drawings. The present invention is intended to cover and include
any and all such modifications and variations to the described
embodiments that are encompassed by the following claims.
* * * * *