Acoustical panel coating and process of applying same

Abstract

A coating composition and process of applying the coating to a substrate are provided herein. The coating composition includes filler particles, binder and a liquid carrier, such as water. The filler particles have an average particle size in the range from about 100 to about 600 microns and preferably in the range from about 200 to about 450 microns. The coating composition comprises from about 15% to about 50% by weight liquid carrier and from about 35% to about 90% by dry solids weight filler particles. The coating composition preserves the acoustic performance characteristics of the substrate to which it is applied, while imparting a textured appearance to the substrate, making the substrate virtually indistinguishable from surrounding panels.

1 - 47 . (canceled)  
   
   
       48 . A method of applying a coating to a substrate, the method comprising the steps of: 
 providing a coating composition having filler particles, binder and a liquid carrier;    spraying the coating composition from a high-volume, low pressure spray apparatus onto a porous substrate; and    drying the coated substrate;    the resulting coated substrate having an airflow resistance value in a range from about 600 mks rayls to 900 mks rayls and a texture value in a range from about 20 ml/sq ft to about 65 ml/sq ft.    
   
   
       49 . The method of  claim 48 , wherein spraying occurs at an atomization pressure in a range from about 10 psi to about 30 psi.  
   
   
       50 . The method of  claim 48 , wherein said coated substrate exhibits a hiding power of about 98% or greater.  
   
   
       51 . The method of  claim 48 , wherein the filler particles have an average particle size in a range from about 100 microns to about 600 microns in an amount from about 35% to about 90% by weight on a dry solids basis.  
   
   
       52 . The method of  claim 51 , wherein the filler particles are selected from the group consisting of calcium carbonate, dolomite and combinations thereof.  
   
   
       53 . The method of  claim 51 , wherein the filler particles exhibit an average particle size in a range from about 200 to about 450 microns.  
   
   
       54 . The method of  claim 48 , wherein the porous substrate is a mineral fiberboard.