AU2015204278A1 - Adhesive strength enhancers for cementitious compositions - Google Patents

Abstract

OF THE INVENTION 5 An adhesion bond strength enhancer for cementitious adhesive mortar is disclosed. The adhesion enhancer improves bond strength between the mortar and relatively hydrophobic plastic material, such as extruded polystyrene boards and expanded polystyrene boards of the type generally employed in Exterior Insulation Finishing Systems ("ElFS"). Preparation of non-caking, free-flowing, solid dialkylisulfosuccinate 10 composiions for use as the adhesion enhancer is also disclosed. The adhesion enhancer is attractive for 'large-scaie application in mineral mortar dry-mixes or other solid construction materials. The invention can be used to improve the strength of an adhesive bond between a) gypsum based plaster or stucco and concrete or bricks, b) tile adhesives and concrete, and c) mineral mortars on polystyrene boards, arnong others.

Description

ADHESIVE STRENGTH ENHANCERS FOR CEMENTITIOUS COMPOSITIONS Background of the Invention 5 The present application is a divisional application from Australian Patent Applcation No. 2012203612, the entire disclosure of which is incorporated into the specification by this cross-reference. 10 Field of the Invention The present invention relates to compositions of matter and methods for increasing the cured adhesion strength, hardness and workability of cementitious compositions, such as masonry cements and mortars. 15 Description of the Related Art Masonry cements and mortars are hydraulic-setting compositions produced particularly for use in bonding of bricks, blocks, and the various components of exterior insulation finishing systems (hereinafter referred to as "EIFS"). Such cements are typically 20 mixed prior to use with a fine aggregate and water. It is desirable that the wet mortar have a high degree of plasticity for working by hand, as well as a relatively a dong working time before the cement hardens. Masonry cements and mortars are produced by grinding Portland cement and gypsum with from about 20 to 65%, of a third material such as limestone, chalk, talc, 25 pozzolans, clay, gypsum, or combinations of such. Portland cement is a type of cement which includes calcined oxides of calcium, aluminum, iron and silicon and is capable of solidifying under water. Such masonry cements are ground to a greater degree of fineness than most Portland cements intended for use in structural concretes. The finer grind of masonry cements improves the plasticity of the finished mortar products, "Exterior insulation finishing system" or "E S" means any one of a number of unique proprietary systems, each of which may consist of specific components associated| with a particular EFS producer. One basic type of EIFS, known as "barrier EIFS", includes boardstock insulation, reinforced adhesive, and exterior coating arranged in three 5 layers. A less common type of ELFS, kno wn as "drainage EIPS", may additionally include plastic edge trim, water-resistive barriers, and water drainage cavities. The boardstock is typically expanded polystyrene or extruded polystyrene. One of the persistent problems in IEFS construction is creating a durable and economical adhesive bond between masonry mortar and polystyrene, I0 The most interior of the three barrier EIFS layers is typically a layer of foam plastic insulation commercially available in the form of polystyrene boardstock. The inner face of the polystyrene boardstock directly contacts a base adhesive (which may be a masonry mortar) and receives mechanical fasteners, such as nails or plugs. An intermediate adhesive filler layer (which may be a masonry mortar) is applied 15 on the outer face of the polystyrene boardstock insulation, typically by means of a trowel. The adhesive filler layer substantially surrounds and fills a reinforcing mesh, which is embedded in the adhesive filler layer. The mesh is typically made of fiberglass and has openings of about one-quarter inch square. Significantly, preparing the adhesive filler, applying the adhesive filer layer to the outer face of the polystyrene boardstock, and 20 embedding the mesh in the adhesive filler layer are generally considered to be demanding and time-consuming tasks for skilled craftsmen. The most exterior of the three layers is a called a topcoat. It is normally a colored and textured paint-like material (which may be a masonry mortar)that is applied with a trowel or, less frequently, by spraying, A wide range of colors and textures are available 25 for the topcoat. Available textures include smooth surfaces, rough stucco-like textures, embedded stone chips, granite-like mixtures and brick-like treatments. US. Patent No. 6,l72,147, issued to Abelleira, describes a masonry mortar additive that contains a multi-stage polymer which includes an ionically-soluble polymer stage, and an air entraining agent. The '147 patent lists many exemplary air-entraining agents 'm CH- M- i t _ AD (referred to collectively in the 147 patent as "AEAs") as suitable for use in the masonry Mortar additive. Among these, listed at Columr 4, lines 3-5 of the '147 patent, are anionic AEAs such as sulfosuccinates. in contrast, a spray-dried dialkyl sulfosuccinlate salt composition of the present invention acts as a deaerating agent upon mixing with a mineral 5 mortar and water (as set forth below in Example 8). US, Patent No. 7,204,065, issued to Naji, describes a method for applying a cementitious formulation to a substrate, such as polystyrene, over a confining mesh attached to the substrate, In certain aspects, such as an aspect claimed in Claim 25 of the '065 patent, the formulation reportedly includes an air entrain ing agent (referred to 10 collectively in the '065 patent as "AEAs"). Among these, listed at Column 6, lines 56-59 of the '065 patent, are anionic AEAs such as sulfosuccinates in contrast, a spray-dried dialkyl sulfosuccinate salt composition of the present invention acts as a deaerating agent upon mixing with a mineral mortar and water (as set forth below in Example 8). Canadian Patent 491099, issued to Vitalis, describes surface-active dialkyl 15 sulfosuccinates compositions that are prepared in the form of dry, non-caking water-soluble powders by spray-drying with sodium benzoate as a hardener at 600-700 degrees F. However, the '099 patent compositions are not panaceas and may yet be improved upon because, among other reasons, they contain sodium benzoate. One objection to the the '099 patent compositions is that sodium benzoate absorbs water in hurnid atmospheres, and 20 caking and clumping rnay be expected if the ambient humidity exceeds 50%. Another objection to the 4099 patent compositions is that sodium benzoate has been associated with skin and eye irritation in dry atmospheres. A need exists for an improved solid surfactant that flows freely under humid atmospheric conditions and dissolves quickly in water. Preferably, the new solid surfactant 25 will strengthen adhesive bonding between masonry mortars and smooth, hydrophobic surfaces such as those used in EIFS. Ideally, the new solid surfactant will increase the hardness and reduce the water uptake of masonry cenents and mortars.

SUMMARY OF THE INVENTION It has fow been discovered that certain additives, herein referred to as adhesion enhancers, can be utilized in cement-based mortars to improve adhesive bond strength between the mortars and relatively hydrophobic plastic materials, such as polystyrene. The 5 adhesion enhances additives may be broadly categorized as surfactant agents, and include dialkyl sulfosuccinates and their salts. The adhesion enhancers of the invention are free flowing solid con positions. Processes for preparing and using the free-flowing, solid adhesion enhancers are described bekw in one aspect, the invention provides a process for forming an adhesive bond 10 between a mortar composition and an article composed of a polymer plastic material, which process comprises: providing a mortar composition that includes mortar and a surfactant composition; which surfactant composition includes a) about 30 to about 75 weight percent of a surfactant selected from the group 15 consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures thereof; and b) carrier particles composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; which carrier particles have a mean average particle size of about 20 0, 1 to about 1000 micrometers and a capacity for carrying an amount by weight of the surfactant that is about 0.2 to about 5 times the weight of the carrier particles; blending the mortar composition with water to produce a wetted mortar composition; and establishing physical contact between the wetted mortar composition and an article 25 composed of a polymer plastic material at conditions effective for curing of the mortar composition, thereby forming an improved adhesive bond between the mortar composition and the article, 41 In another aspect, the invention provides an adhesive bond formed by the process as described above. In yet another aspect, the invention provides a process for deaerating a mixture that includes mineral mortar, water and air, which process comprises: 5 mixing a surfactant composinion with mineral mortar, water and air at an active use level of about 0.01 weight percent to about 0,5 weight percent; which solid surfactant composition includes a) about 30 1o about 75 weight percent of a surfactant selected from the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures 10 thereof; and b) carrier particles composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; which carrier particles have a mean average particle size of about 0 I to about 1000 micrometers and a capacity for carrying an amount by weight of the surfactant that is 15 about 0.2 to about 5 times the weight of the carrier particles. The invention generally relates to a free-flowing solid surfactant composition that includes a surfactant and carrier particles. The surfactant may be one or more alkyl sulfosuccinates, one or more salts of alkyl sulfosuccinates, or a mixture of these. The carrier particles are composed of an absorbent calcium carbonate, calcium silicate, silicon 20 dioxide, kaolin, or mixtures of these. The carrier particles have a mean average particle size of about 0,1 to about 1000 micrometers, and a capacity for carrying an amount by weight of the surfactant that is preferably about 0.2 to about 5 times the weight of the carrier particles. The invention also generally relates to a free-flowing solid surfactant composition 25 that includes about 30 to about 75 weight percent of a surfactant composed of alkyl sulfosuccinates, salts of dialkyl sulfosuccinates, or mixtures of these. The composition also includes about 10 to about 75 weight percent of carrier particles which are composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, or mixtures of these, The carrier particles have a mean WSOM~ QHN~ws average particle size of about 1to about 160 micrometers, and the capacity to absorb an amount by weight of the surfactant that is about 0.2 to about 4 times the weight of the carrier particles. In addition, the composition includes about I to about 10 weight percent of an anticaking agent. 5 The invention also generally relates to a dry-mix mortar composition including a dry-mix, hydraulic-setting mortar or cement, a solid surfactant composition as described above, and an anticaking composition. The invention also generally relates to a process for manufacturing a free-flowing solid surfactant composition. The process includes introducing a surfactant selected from 10 the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures thereof into an absorption zone. Carrier particles are also introduced into the absorption zone. The carrier particles are composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin and mixtures thereof; have a mean average particle size of about 0.1 to about 1000 micrometers; and 1 5 have a capacity for carrying an amount by weight of the surfactant that is about 0.2 to about times the weight of the carrier particles. The surfactant and the carrier particles are maintained in the absorption zone at conditions effective for absorption of the surfactant by the carrier particles to produce solid surfactant particles. An anticaking agent is optionally mixed with the solid surfactant particles to produce a free-flowing solid surfactant 20 composition. The invention also generally relates to a process for manufacturing a free-flowing solid surfactant composition by spray-drying a liquid solution including a surfactant selected from the group of dialkyl sulfosuccinates and salts thereof in the presence of carrier particles, and optionally anti-caking agents, to produce a free-flowing solid 25 surfactant composition. A defoamer, a non-ionic surfactant, or both maybe blended with liquid solution. The invention also generally relates to a process for forming an adhesive bond between a mortar composition and an article composed of a polymer plastic material The process involves providing a mortar composition that includes a solid surfactant 30 composiion as described above, and establishing and maintaining physical contact between 6 SA,$823! . IafA} P3 5WAURRIS the cement composition and an article composed of a polymer plastic material at conditions effective for curing of the mortar composition. The invention also generally relates to an adhesive strength enhancer for hydraulic setting materials. For example, the invention can be used to improve the strength of an 5 adhesive bond between a) gypsum based plaster or stucco and concrete or bricks, b) tile adhesives and concrete, and c) mineral mortars on polystyrene boards. DETAILED DESCRIPTION OF PREFERRED ASPECTS OF THE INVENTION In a preferred embodiment, the invention is a free-flowing solid surfactant 10 composition that is useful as an adhesion enhancer for cementitious mortars and that includes a surfactant and carrier particles. Because the construction industry is well equipped to handle pre-mixed mortars and cements that arrive at ajob site in powder form, the free-flowing quality of this adhesion enhancer is highly desirable. The surfactant includes one or more alkyl sulfosuccinates, and/or one or more salts 15 of alkyl sulfosuccinates, Preferably, the alkyl sulfosuccinates and the salts are dialkyl, more preferably dialkyl with alkyl carbons atoms totaling 16 to 32 per molecule, Dioctyl succinate, didecyl succinate, and their sodium or ammonium salts are especially preferred. For the present purposes, "alkyl carbon atom" means a carbon atom situated within an alkyl ligand of a sulfosuccinate moiety. 20 The surfactant is preferably present in an amount of about 30 to about 75 weight percent, based on the total weight of the solid surfactant composition; more preferably about 35 to about 65 weight percent; and most preferably about 45 to about 55 weight percent. The carrier particles are composed of calcium carbonate, calcium silicate, silicon 25 dioxide, kaolin or mixtures of these. The carrier particles should have a mean average particle size of about 0,1 to about 1000 micrometers, preferably about I to about 200 micrometers, most preferably about 10 to 160 micrometers. A typical preferred particle size distribution includes 50% of particle below 4 micmeters, 95% of particles below 26 micrometers, and 100% of particles below 56 micrometers. Carrier particles less than I micrometer are not recommended for use in the invention because they cause dusting problems and are sometimes associated with risks to 5 human health. Also, these extremely smalN particles tend to settle out of mixtures with other solids, rather than distribute homogeneously as is necessary for use in mortar and cement mixtures. Ideally, the solid surfactant composition will be a particulate with the same particle size distribution as a mortar or cement to which it is added. The carrier particles are preferably present in an amount of about 10 to about 75 10 weight percent, based on the total weight of the solid surfactant composition; more preferably about 20 to about 60 weight percent; most preferably about 25 to about 55 weight percent. The carrier particles preferably have a capacity for carrying an amount by weight of the surfactant that is about 0.2 to about 5 times the weight of the carrier particles, more preferably about I to about 4 times the weight of the carrier particles, most preferably 15 about I to about 3 times the weight of the carrier particles. The carrying capacity of the carrier particles is a key factor for adjusting the rate at which the surfactant dissolves when a solid surfactant composition of the present invention is immersed in water or any other solvent. For chemical operators in general, and construction crews that mix mortar and cement in particular, a relatively rapid dissolution 20 is highly desirable, Dissolution of the surfactant from carrier particle tends to be more rapid from carrier particles that have lower carrying capacity. On the other hand, solid surfactant compositions in which the carrier particles have too low a carrying capacity tend to cake and clump, rather than flow freely. As set forth above, the carrier particles preferably have a mean average particle size 25 of about 0.1 to about 1000 micrometers and a capacity for carryirig an amount by weight of the surfactant that is preferably about 0.2 to about 5 times the weight of the carrier particles In addition, the inventors have found that suitable carrier calcium carbonate particles in this size range usually have about a specific surface area of about 0 1 to about 15 square meters per grand Suitable silicon dioxide particles in this size range usually have 8 a specific surface area of about 100 to about 600 square meters per gram. For calcium silicate, suitable carrier particles usually have a specific surface area of about 100 to about 300 square meters per gram, In the case of kaolin, suitable particles usually have specific surface area of up to 20 square meters per gram. 5 In addition, the solid surfactant composition preferably includes an anticaking agent. For the present purposes, "anticaking agent" means a material that tends to prevent agglomeration of certain solids, thereby promoting flowability of the solids. Without intending to be bound by theory, it is believed that anticaking agents function by adsorbing excess moisture, or by coating particles and making then water repellent. Examples of 10 useful anticaking agents include calcium silicate, silicon dioxide, magnesium oxide, magnesium or calcium stearates, kaolin and bentonites. Some anticaking agents can serve two or more purposes, such as absorbing liquids and promoting flowability. Hydrophobic silicon dioxide is especially preferred as an anticaking agent. The anticaking agent is preferably present in an amount of about I to about 10 15 weight percent, based on the total weight of the solid surfactant composition; more preferably about 4 to about 8 weight percent. In another preferred aspect, the invention is a dry-mix, hydraulic-setting mortar or cement composition. The dry-mix position is in powder or granulated form, and includes a hydraulic-setting, dry-mix mortar or cement; a solid surfactant composition as described 20 above; carrier particles as described above; and an anticaking agent as described above. Preferably the solid surfactant composition includes about 0.1 to about I wt%, preferably about 0.2 to about 0.8 wt%, and more preferably about 0.3 to about 0.7 wt% of alkyl sulfosuccinates and/or salts of alkyl sulfosuccinates, based on the total weight of the dry mix composition. 25 The inventors have discovered that the presence of about 0. 1 to about I wt%, dioctyl sulfosuccinates, didecyl sulfosucinates, and/or salts of these sulfosuccinates in a dry-mix composition of the invention significantly increases the adhesive strength of a hydraulically-set mortar or cement produced from the dry-mix composition, as compared to hydraulically-set mortar or cement produced from a dry-mix composition that includes no 9 MM63,0: Ms s)s PS32U1 SMORRS dioctyl sulfosuccinates, no didecyl sulfosucinates, and no salts of these sulfosuccinates ne of these sulfosuccinates but is otherwise identical. Additional information regarding this discovery is provided below in Example 5, Example 6, and Example 7, among other places. In yet another preferred embodiment, the invention is a process for manufacturing a 5 free-flowing solid surfactant composition. The process includes introducing a surfactant selected from the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures these sulfosuccinates and/or salts into an absorption zone. The surfactant may be introduced in liquid form, in solid form, or as a solute in a liquid solution. Suitable surfactants are described above with regard to a solid surfactant composition. 10 Carrier particles are also introduced into the absorption zone. The carrier particles which are composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; have a mean average particle size of about 0.1 to about l000 micrometers, and have a capacity for carrying an amount by weight of the surfactant that is about 0:2 to about 5 times the weight 15 of the carrier particles into the absorption zone. Suitable carrier particles are described above with regard to the solid surfactant composition. The surfactant and the carrier particles are maintained in the absorption zone at conditions effective for absorption of the surfactant by the carrier particles to produce a free-flowing solid surfactant composition. The effective conditions may include mixing, 20 kneading, agitating or spray-drying the surfactant with the carrier particles. Preferably, conditions effective for spray-drying the surfactant with carrier particles are maintained in the absorption zone. Optionally, an anticaking agent, such as hydrophobic silicon dioxide, is introduced into the absorption zone, where it is mixed with the solid surfactant particles to promote flowability. 25 When conditions effective for spray-drying the surfactant with the carrier particles are maintained in the absorption zone, the surfactant is preferably introduced as a solute in an aqueous solution. A defoamer, a non-ionic surfactant, or both may be blended with the liquid solution, Preferably, a fluidized bed of surfactant solution droplets and carrier particles is maintained in the absorption zone at a temperature that is cool enough to permit 30 absorption of the solution into the carrier particles and warm enough to evaporate the 10 solution the solution at a commercially practical rate. The concentration at which the solution is introduced, the temperature at which the solution is introduced, the relative sizes and amounts of the solution droplets and the carrier particles, and the superficial velocity and inlet temperature of fluidizing gas are factors in determining the effective conditions. 5 These factors and techniques for their optimization are known to practitioners in the art of fluidized bed spray-drying. When conditions effective for concentrating a liquid surfactant by vacuum drying, rotary evaporator drying, or similar drying techniques are maintained in the absorption zone; the surfactant is preferably introduced as a sulfosuccinate solution or a sulfosuccinate 10 salt solution. The solution is preferably mixed, kneaded, shaken or otherwise agitated with absorbent carrier particles. Additional ingredients, such as a defoaming agent or a non ionic surfactant, may be introduced into to the absorption zone directly, or introduced into the absorption zone via the sulfosuccinate salt solution . It is possible to produce free flowing solid surfactant particles without removing al of the solvent from the particles, 15 In still another preferred aspect, the invention is a process for forming an adhesive bond between a hydraulic-setting, cementitious mortar composition and an article composed of a polymer plastic material. The polymer plastic material may be composed of, for example, expanded polystyrene or extruded polystyrene, and may be incorporated in a system, such as an exterior insulation finishing system. 20 In the process, a mortar composition is provided that includes a solid surfactant composition as described above, Physical contact is established between the mortar composition and the article composed of a polymer plastic material. This contact is maintained at conditions effective for curing of the mortar composition, thereby forming an improved adhesive bond between the mortar composition and the article, Preferably, the 25 conditions effecetive for curing the mortar composition inicude maintaining a temperature warmer than 32 degrees F, for a period of about I to about 30 days. The conditions effective for curing of the mortar composition are welI known to practitioners in the field of cement and mortar formulation.

The folowing examples are presented to better communicate the invention, and are not meant to limit the invention in any way. Unless otherwise indicated, al references to parts, percentages or proportions are based on weight. Examples S r~artv -yh Sloucitt Sl oution with Part-icles The following procedure (hereinafter referred to as "Procedure I") is performed for preparing solid formulations of the invention, An aqueous dialkyl sulfosuccinate salt solution is spray dried with can-ier particles and/or anti-caking particle in a fluidized bed to produce a free-flowing solid formulation with good caking resistance. For the present 10 purposes, this dialkyl sulfosuccinate salt is referred to as "active ingredient". Optionally, additional ingredients such as surfactants, spray-drying aids or anti-foaming agents may be added to the contents of the fluidized bed in order to modify the physical or chemical properties of the solid formulation. The flow rates and temperatures of the fluidized bed, and of streams entering the fluidized bed, were optimized and maintained by techniques 15 well-known to practitioners in the art of spray-drying. Table I, below, summarizes the sulfosuccinate salts and particles introduced into the fluidized bed spray drier for specific procedures Ia through Ie, based on the mass of the solid formulations produced by the procedure TABLE 1: Preparation of Strength Enhancer by Spray-Drying Solution with Particles ---------------------------- %-------- _7 --------------------------------------------- N. . . . . . . ErrcedreActveActive CaCO 3 ~ n ~ Comments No Ingredient Ingredient Particles Particles (chemical (mass% (mass% of (mass% of name) of product product) product) I a Diisodecyl 37 7 mass% 545 mass% 7 8 mass% Product is a ammonium free-flowing sulfosuccinate solid of the INVENTION Diisodecyl 38 5 mass% 57.0 mass% 4.5 rnass% Product is a ammonium free-flowing sulfosuccinate solid of the INVENTION Diisootyi 45 massO 51 .2 mass% 3 7 mass% Product is a 12 sodium free-flowing sulIfosuccinate solid of the INVENTION d Diisooctyl 31 8 mass% 648 rnass% 3 4 mass% Product is a sodium free-flowing sul fosuccina e solid of the INVENTION e Diisooctyl 53 0 mass% 433I mass% 3 3 mass% Product is a sodium free-flowing sulfosuccinat solid of the INVENTION Legend: * precipitated calcium carbonate particulate commercially available frorn Ornya Hamburg GmbH of Hamburg Germany under the tradename Omyacarb* + hydrophobic precipitated silicon dioxide particulate commercially 5 available from Evonik Degussa Corporation of Wesseling, Germany under the tradename Sipernat" The data of Table I above demonstrates that free-flowing, solid formulations of the invention can be produced by spray-drying an aqueous dialkyl sulfosuccinate salt solution 10 with carrier particles and/or anti-caking particles in a fluidized bed. Prjprative Exam-ple 2:g Ahmixi lfn NxinatQ St alMion iWbE tde The following procedure (hereinafter referred to as "Procedure 2") is performed for preparing solid formulations of the invention. Particulate solids with a favorable absorption capacity for oleaginous liquids and desirable flow properties are introduced into t5 a mixing or kneading device. A liquid solution including a dialkyl sulfosuccinate or a dialkyl sulfosuccinate salt is added to the particulate solids while mixing, kneading or otherwise agitating the contents of the device proceeds. The liquid solution is absorbed into the absorbent particles to produce free-flowing solid formulations with good caking resistance. Optionally, additional ingredients such as surfactants or anti-foaming agents are 20 added to the contents of the device in order to modify the physical or chemical properties of the solid formulations. Table 2, below, summarizes the solutions, the absorbent particles, the additional ingredients (if any), and the solid formulations of specific procedures. TABLE 2: Preparation of Strength Enhancer by Admixing Solution with Particles X. km, "A N N V"R tt Procedure Active Active CaSiO 3 SiO2 Comments No, Ingredient Ingredient Particles Particles (concentration (mass% (mass% of (mass% of' in starting of product product) product) solution) 2a Diisodecyl 25 mass% 0 mass% 50 mass% Product ammoium contains 25% sulfosuccinate solvent and is (50%) a free-flowing solid of the INVENTION 2b Diisodecvl 30 mass% 0 mass% 50 mass% Product ammon mum contains 20% suLifosuccinate solvent and is (60%) a free-flowing solid of the INVENTION 2c Diisooctyl 40 mass% 42 mass% 0 mass% Product sodium contains 18% sul fosuccinate solvent and is (70%) a free-flowing solid of the UNV/ENTIO0N Legend: * precipitated calcium silicate particulate commercially available from JM. Huber Corporation of Oostende, Belgium under the tradename Zeofree* + hydrophobic precipitated silicon dioxide particulate commercially available from Evonik Degussa Corporation of Wesseling, Germany under the tradename Sipernat* The data of Table 2 above demonstrates that free-flowing, solid formulations of the invention can be produced by adrnixing an aqueous dialkyl sulfosuccinate salt solution in 10 liquid for with absorbent carrier particles and/or absorbent anti-caking particles. Pr--,arat ive xamIle 3:Je Bn I;............... Dried iv Sulfosuciinate Salt with-Particles The following procedure (hereinafter referred to as "Procedure 3") is performed to prepare solid formulations of the invention. A dialkyl sulfosuccinate salt solution is dried 15 to produce a wax-like solid, comminuted as necessary, and blended with particles having desirable flow properties to produce a free-flowing solid formulation with good caking resistance. Optionally, additional ingredients such as surfactants or anti-foaming agents are 14 added to the contents of the mixer in order to modify the physical orchemical properties of the solid formulation. Table 3, below, summarizes the dried dialkyl sulfosuccinate salts, the particles, he additional ingredients (if any). and the solid formulations produced by specific procedures. 5 TABLE 3: Preparation of Strength Enhancer by Blending Dried Salt with Particles I ------------------------------------------- -------------------------------------------- -------------- Activ Kaolin Ca6C0 SIO2 Comments Procedure Ingredient Particles Particles Paricles No (mass% (mass% (rnass% of (mass% of of product) of product) product) product) 3b Diisodeeyl 0 mass% 34 mass% 0 mass% Product is a amnioniurn free-flowing sulfosuccinate solid of the / 66 mass% INVENTION 3c Diisodecyl 0 mass% 55 mass% 8 mass% Product is a ammoniurn free-flowing sulfosuccinate solid of the /37 mass% INVENTION 3d Diisooctyl 0 nass% 0 rnass% 50 rnass% Product is a sodium free-flowing suifosuccinate solid of the 50 mass% INVENTION 3C Diisooctyl 0 mass% 34 mass% 0 mass% Product is a sodium free-flowing sulfbsuccinate solid of the 66 mass% INVENTION Diisooctyl 0 mass% 35 mass% 5 mass% Product is a sodium free-flowing sulfosuccinate solid of the 60 mass% INVENTION Diisooctyl 50 mass% 0 mass% 0 mass% Product is a sodium free-lowing sulfosuccinate solid of the / 50 rnass% INVENTION Legend: ~ hydrated aluminium silicate particulate commercially available from KaMin LLC of Macon, Georgia, U.S.A. under the tradename KaMirM 90 precipitated calcium carbonate particulate commercially available from Omya Hamburg GmbH of Hamburg, Germany under the tradename Omycarb* + hydrophobic precipitated or fumed silicon dioxide particulate commercially available from Evonik De ussa Corporation of Wesseling, Germany under the tradenames Sipernat* and Aerosil* 15 6M3 G(J Anv P07 52AU1 MORIS The data of Table 3 above demonstrates that free-flowing, solid formulations of the invention can be produced by blending a dried diakyl sulfosuccinate salt solution in solid form with carrier particles and/or anti-caking particles. 5 P'aQ xamIe.4: ing P k Vriddbesrg b Bond hgh 5rg b The fovoing performance testing procedure (hereinafter referred to as "the Testing Procedure") is performed in order t determine the effect of ar adhesive bond strength enhancer on an adhesive bond between a cement composition and a board composed of expanded or extruded polystyrene. In the procedure, solid strength enhancers 10 are pre-mixed for about one minute with a dry cement composition. in either case, the cement composition is selected from mineral adhesive and reinforcement mortars, such as "BAUMIT Adhesivefiller ("Klebespachtel")TM" and "BA UMIT Adhesivefiller Allround ("Klebespachtel Allround"),v which are commercially available from Baum it. The mineral mortar is added to water in a ratio of 4 to I and mixed for one minute. in each 15 trial, an active concentration use level of 0.3 to 0.6 mass% dialkyl sulfbsuccinate salt is utilized. A 2 to 3 mm wet mortar layer is applied evenly on an expanded or extruded polystyrene board, such as an extruded XPS polystyrene board commercially available form BASF under the tradename "Styrodur 3035 CS." The wet mortar test specimens are 20 dried over a period of 7, 14 or alternatively 28 days. At the end of the drying period, the adhesive strength of the bond between the mortar and the expanded polystyrene board is measured in accordance with test protocol DIN EN ISO 4624:2003. A pull-off adhesion tester is employed in the protocol. Each of the tests is conducted in general 6 to 10 times with a strength enhancer of interest, and the same number of times without any strength 25 enhancer For comparison. An adhesion enhancement value (in units of percentage increase) is calculated by dividing the mean average of results for each test with strength enhancer by the mean average of test results without strength enhancer, subtracting one, and multiplying the difference times 100. Employing the Testing Procedure, adhesion enhancement values are determined for 30 various spray-dried dialkyl sulfosuccinate salts and presented in Table 4, below. 16 - W ,M_ it; o PMM 7 U TABLE 4: Adhesion hIcrease for Spray Dried Dialkyl Sudfsuccinte Sats n ineral Mortar on Poicstyrenesf oards -- - - - - - -- - - - - - --- -- - -- - - - - -- - - - Tes Strergth Mineral MortarX or EPS Dry Aetve Adhesion No Enhancer Prodt Name (Producer Time |ise- increase active content (Producer) Board Name Level (percent) sidform 4a DDSSKiebesp actel XPS 28 0 5% 42% 3%) Allround (BASF/ days (Baurni 3035 CS) 4b Debespachtel XPS 28 0 5% +48% 45%) Ardays (Baumit) 3035 CS 4c DOSS Khep~tl XPS 14 0,5% + 65 % 45% Afround (Dow/Austro days _____ ~(Baurnito thermTon P) _______ e j DOSS STOlevel Urn ~ps 2S 04 4 45%) (Stos) (Sto/ das 0,5% P)S30SE) 4e DOSS STOlevell Uni XPS 28 0 4% +48 % (45%) (Sto) (BASF/ days 3035 CS) 4f DOSS Capatect XPS 8 05% +58% (DA W 6 ) (BASF/3035 days _____CS) 4 DOSS Comb Put 499 EPS 7 0,5% + % (45%) (Grautol (reuol) days 4h DOSS UCnihi Putz 499 XPS 7 0,5%' 44 % (45%) (reuit) (BASE] days 3035 CS) 4i DOSS Kiebe spachtel XPS 7 0,5% 9 (45%) (Quarzoih&) (BAS F! days ____ ____________ _________3035 CS) 4k DOSS Klebespachtel XPS 28 0 3% + 30 % (45%) (St Gobain9) (Weber- days Terranova 41 DOSS WDVS XPS 14 0 5% 62 % (45%) Pulverklebor (BASF/ days 3550 (Brilux) 3035 CS) 4 DOSS Klebemortel 804 XS 14 0.6% 54 (45%) (Hasit" (BASE! days 3035 CS) Legnd I Adhesion increase is calculated by dividing the mean average of test runs with sulfosuccnate-containing mortar by the mean average of test runs 5 having no sulfosuccinate and expressing the quotient as a percentage, 2 DDSS means dilsodecyl ammonium sulfosuccinate in solid form, of 38% active content, produced by the spray-drying process described above in Example 1. 3 DOSS means diisooctyl sodium sulfosuccinate in solid form, of 45% 5 active content, produced by the spray-drying process described above in Example I. 4 Baumit means Wietersdorfer & Peggauer Zementwerke GmbH, A-9373 Klein, St. Paul 5 Sto means STO AG, Ehrenbachstrafe, I D-79780 Stablingen 10 6 DAW means Synthesa Chemie Ges.m.b.H, Dirnbergerstra'3e 29-31, A-4320 Perg 7 Greutol means Greutol AG, Libernstrage 28, C-1-8 112 Otelfingen 8 Quarzolith means Quarzolith SUd Gmb-l, Mitterdorferstrafe 1, A-8572 Burnbach 15 9 St. Gobain means Saint Gobain, Weber Maxit, Gleichentheilgasse 6, A-] 230 Wien 10 Brillux means Brillux GmbH & Co. KG, Weseler Strale 401. D-48163 Minster I I Hasit means Hasit Trockenmartel GmbH, Karl-Knab-Strae 44, 20 D-92521 Schwarzenfeld Inspection of Table 4 above reveals that diisodecyl sodium sulfosuccinate in solid form of 38% active content, and diisocetyl sodium sulfosuccinate in solid form of 45% active content, produced by the spray-drying process described above in Example 1 25 significantly increase the strength of an adhesive bond between a polystyrene board and a variety of commercially available mineral mortar products. erformance Fxma:ja p Tinhj of SaAh eBond Se lh dancers In order to determine the effect of use-level on adhesive strength, the Testing Procedure described above in Example 4 is performed for various use-levels of a particular 30 spray-dried solid surfactant composition in a certain mineral mortar on identical polystyrene boards, In the procedure, a solid surfactant composition produced by spray-drying an aqucous solution of dioctyi sulfosuccinate salt with a calcium carbonate carrier is pre mixed for about a minute with a dry-mix, hydraulically-setting, cementitious mineral 35 mortar composition that is commercially available under the trade name "BAUMIT Adhesivefiller Allround" from Baumit. The mineral mortar is added to water in a ratio 18 of 4 to i and mixed for one minute. In each trial, an active concentration use-level in the range of 0.1 to 0,8 mass% of dioctyl sulfosuccinate salt is utilizecd A 2 to 3 mm wet mortar layer is applied evenly on an extruded polystyrene board commercially available from Dow under the trade name Austrotherm Top P. The wet 5 mortar test speciEnens are dried over a period of 7 days. At the end of the drying period, the adhesive strength of the bond between the mortar and the extruded polystyrene board is measured in accordance with test protocol DIN EN ISO 4624:2003 using a pull-off adhesion tester. An adhesion enhancement value (in units of percentage increase) is calculated by dividing the mean average of results for each test with strength enhancer by 10 the mean average of test results without strength enhancer, subtracting one, and multiplying the difference Limes 100. Employing the Testing Procedure, adhesion enhancement values are determined for a various use-levels of a particular spray-dried dioctyl sulfosuccinatesalt in a certain mineral mortar on identical polystyrene boards and presented in Table 5, below, 15 TABLE 5: Adhesion Increase for Various Use-Levels of Spray-Dried Dioctyl Sulfosuccinate Salt in a Mineral Mortar on a Poiystyrene Board Test Strength Mineral Mortar XPS Dry Active Adhesion No. Enhancer Product Name (Producer/ Time Use- Increase (active content (Producer) Board Name) Level (percent) of solid form) 5a DOSS' Kiebespachtel XPS 7 0.1% +4% (45%) Allround (Dow/Austro- days (Baumit 3 ) therm Top P) -------- ---- 5b DOSS Klebespachtel XPS 7 0.2% +38% (45%) Allround (Dow/Austro- days (Baunit) therm Top P) 5C DOSS Klebespachtel XPS 7 0,3% +44% (45%) Allround (Dow/Austro- days (Baurnit) therm Top P) 5d DOSS Klebespachtel XPS 7 0.4% +46% (45%) Alround (Dow/Austro- days (Baum) i therm Top P) 5e DOSS Klebespachtel XPS 7 0.5% +51 % (45%) Allround I (Dow/Austro- days (Baumit) therm Top P) 5f DOSS j Klbespachte | XPS 7 0.6% + 43 % (45%) Allround (Dow/Austro- days .......... 19 _ - ------------------ (Baum it) therm Top P) Sg DOSS Klebespachtel XPS 7 0 % +35% (45%) Alhround (Dow/Austro- days (Baumit therm Top P) 5h DOSS Klebespachtel XPS 7 08% 22 % (45%) Alround (Dow/Austro- days (Baumit) therm Top P) Legend: I Adhesion Increase is calculated by dividing the mean average of test runs with sulfosuccinate-containing mortar by the mean average of test runs having no sulfosuccinate, and expressing the quotient as a percentage. 2 DOSS means diisooctyl sodium sulfosuccinate in solid form, of 45% 5 active content, produced by the spray-drying process described above in Example 1 3 Baumit means Wietersdorfer & Peggauer Zementwerke GmbH, A-9373 Kein, St. Paul 10 Inspection of Table 5 above reveals that addition of dioctyl sulfosuccinate salt in solid form, in the range of 0,22 to 1.78 mass Strength Enhancer use-level, significantly increases the strength of an adhesive bond between a polystyrene board and a commercially available dry-mix mineral mortar product. Based on this data, it appears that an anomaly for adhesive strength enhancement exists in the range of about 0.1 to about I mass% active I5 use-level. Performance Ex ml6: Uefr iw et iof Adrn:ixed Bond Strnt -;-Enh ancers The Testing Procedure described above in Example 4 is performed with a free flowing, solid adhesive bond strength enhancing composition prepared by the process described in above in Example 2 in order to determine the effect of these compositions on 20 an adhesive bond between a cementitious composition and a board composed of extruded polystyrene. Employing the Testing Procedure at two different use levels of a dialkyl sulfosuccinate salt, adhesion enhancement values are measured and presented in Table 6 below. TABLE 6: Adhesion increase for Admixed Dialkyl Sulfosuccinate Salts 25 in Mineral Mortar on Polystyrene Boards Test Strength | Mineral Mortar XPS or EPS Dry Active Adhesion No. Enhancer Product Name (Producer/ Time Use- Increase (mass%) / (Producer) Board Name) Level (percent) 6a DDSS 2 Kle be spaCTXPS 7 5% +27% 20 (2 5%)/ Allround (BASF! days .. S...(Baumi..) 3035 CS) 6b DDSS Klebespachtel I XPS 28 0.5% 2% 25%)/ Alround (BASF/ days ___ __ Si________ (Baumit) 3035 CS) _______ 6c DDSS Klebespachtel XPS 7 0.5% + 26% (30%)! Allround (BASF/ days Si00 (Baumit) 3035 CS) 6d DDSS Klebespachte! XPS 28 0,5% +28% (30%)! Around (BASF/ days SiO& (Baumit) 3035 CS) 6e DOSS' , Klebespachtel XPS 14 0.5% IN0 (40%)! CaSiO* Allround (BASF/ days (Baumit') 3035 CS) 6f DOSS Klebespachtel XPS 14 0.6% 35% (40%)! CaSiO3* Allround (BASF/ days (Baunit) 3035 CS) Legend: I Adhesion Increase is calculated by dividing the mean average of test runs with sulfosuccinate-containing mortar by the mean average of test runs having no sulfosuccinate, and expressing the quotient as a percentage. 2 DDSS means diisodecvl ammonium sulfosuccinate in solid form, of 5 25 or 30% active content, produced by admixing of a sulfosuccinate salt solution with absorbent particulate as described above in Example 2, 3 DOSS means diisooctyl sodium sulfosuccinate in solid form, of 40% active content, produced by admixing of a sulfosuccinate salt solution with absorbent particulate as described above in Example 2. 10 4 Bauniit means Wietersdorfer & Peggauer Zementwerke GmbH, A-9373 Klein, St. Paul * hydrophobic precipitated silicon dioxide particulate commercially available from Evonik Degussa Corporation of Wesseling, Germany under the tradename Sipernata 15 precipitated calcium silicate particulate commercially available from JM, Huber Corporation of Oostende Belgium under the tradename Zeofree* The results presented in Table 6 are proof that a dry, free-flowing, solid composition prepared by the admixture process described above in Example 2 significantly 20 increases the strength of an adhesive bond between a polystyrene board and a commercially available mineral mortar product. *~gydraE.......: Testimngof Dried Sultb~ssuccinate Salts Blended witmh Particulate Various dried dialkyl sulfosuccinate salts are blended with solid carrier materials in accordance with Procedure 3, which is described above in Preparative Example 3 21 %%% (GXerg P92T2AUSMR~i Adhesion enhancement values are determined for the dried dihakyl sulfosuccinate salts with solid carrier maters in accordance with the Testing Procedure, as set forth above in Example 6. In each trial, an active concentration of 0,5Mrass% dried dialkyt sulfosuccinate sat is utilized. The resulting adhesion enhancement values are presented in Table 7 below, 5 TABLE 7: Adhesion Increase for Dried Dialkyl Sulfosuccinate Salt with Particles in Mineral Mortar on Pol styrene Boards est Strength Mineral Mortar XPS or BPS Dry Active Adhesion No Enhancer Product Name (Producer/ Time | Use- Increase' (mass%)/ (Producer) Board Name) Level (percent) Particle massr) 7a DDSS Klebespachtel XPS 7 0,5% + 37% (66%)/ Allround (BASE! days CaCO 3 (Baumit) 3035 CS) (3 4 % ) ........................................ DDSS Klebespachtel XPS 28 0.5% + 30% 7b (66%)/ Allround (BASF/ days CaCO, (Baumit) 303 5 CS) (34%) DOSS K bespachtel XPS 7 0.5% + 49% 7c (66%)/ Allround (BASF/ days CaCO 3 (Baumit) 3035 CS) (34%) DOSS Klebespachtel XPS 28 0,5% + 37% 7d (66%) / Allround (BASF/ days CaCO (Baumit) 3035 CS) (34%) DOSS Klebespachtel XPS 0.5% . 23% 7e (50%)/ Allround (BASF/ days Kaolin clay (Baumit) 3035 CS) DOSS Klebespachtel XPS 7 0.5% + 16% 7f (50%) Atround (BASF/ days S o,(Baumit) 3035 CS) (50%) _________ _______ ___ _ _ Legend: I Adhesion Increase is calculated by dividing the mean average of test runs with sulfosuccinat-containing mortar by the mean average of test runs having no sulfosuccinat and exposing the quotient as a percentage 10 2 DDSS means diisodecyl ammonium sulfosuccinate in solid form, produced by blending dried diisodeeyl arnnnium sulfosuccinate with particulate as described above in Exap1le 3. Rf,,~~ Nk'x 3 DOSS means diisoocty sodium sulfosuccinate in solid form, produced by blending dried diisooctyl sodium sulfosuceinate with particulate as described above in Example 3, 4 Ba;unit means Wietersdorfer & Peggauer Zene.ntwerke GmbH, 5 A-9373 Klein, St. Paul * precipitated calcium carbonate particulate commercially available from Omya Hamburg GmbH of Hamburg, Germany under the tradename Omyacarb* ** hydrated aluminium silicate particulate commercially available from 10 KaMin LLCI of Macon, Georgia, U.S.A. under the tradename KaMin m * hydrophobic fumed silicon dioxide particulate commercially available from Evonik Degussa Corporation of Wesseling, Germany under the tradename Aerosil* 15 Based on the results presented above in Table 7, one may reasonably conclude that the presence of dry, free-flowing, solid compositions prepared by the dry blending process described above in Example 3 significantly increases the strength of an adhesive bond between a polystyrene board and a commercially available mineral mortar 20 product. Performance Examp,,le & DeaeratinFfet. oF S ray idjjcy Sfoccinate Salt A solid surfactant composition that contains 45% diisooctyl sulfosuccinate salt prepared in accordance with Procedure I, set forth above in Preparative Example 1. In 25 various demonstration tests, the solid surfactant composition is mixed at known concentrations for one minute with a mineral mortar and water that are present in a proportion of 421, and the volume of the mixture is measured. The volumes are set forth below in Table S. TABLE 8, Mineral Mortar Volurne Test Strength Mineral Mortar Active use- Volume No. Enhancer Product Name level (milliters) Active (Producer) (percent in Ingredient mixture) (mass%) 8a DOSS' Klebespachtel 0.000% 61 ml (45%) Allround (Control) _-----_------- (B a u m it 2 ) ............... 23 W 1 (GHFts37)52AU4SMORR DOSS Klebespachtel 0 0% 6 (45%) Adround (Baumit) DOSS Klebespachtel 0 025% St 5 (45%) Allround (Baumit) DOSS Klebespachtel 0,050% 54 (45%) Allround (Baumit) DOSS Kiebespachtel 0,075%' ------ -------- (45%) Allround (Baumit) DOSS Kl~bespachtel 0.100% tj5%) A I i ro- ti d DOSKlebe', p a chte1 0,250% (45%) Allround (Baumit) DOSS Klebespachtel 0500% (45%) Allround (Baum it) eLend DOSS means diisooctyl sodium sulfosuccinate in solid form, of 45% active content, produced by the spray-drying process described above in Example L Baumit means Wietersdorfer & Peggauer Zementwerke GmbH, A-9373 Klein, St. Paul The results presented above in Table 8 indicate that a solid surfactant composition of the invention acts as a deaerating agent upon mixing with a commercially available mineral mortar and water, In fact, the concentration of diisooctyl sulfosuccinate in the mixture is directly proportional to the deaeration. The above Examples are intended to better communicate the invention, and do not limit the invention in any way. The invention is defined solely by the appended claims.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication form: a part of the common general knowledge in the art, in Australia or any other country. 5 In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 10

Claims (42)

1. A process for forming an adhesive bond between a mortar composition and an 5 article composed of a polymer plastic material, which process comprises: providing a mortar composition that includes mortar and a surfactant composition; which surfactant composition includes a) about 30 to about 75 weight percent of a surfactant selected from the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures 10 thereof; and b) carrier particles composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; which carrier particles have a mean average particle size of about 0. 1 to about 1000 micrometers and a capacity for carrying an amount by weight of 15 the surfactant that is about 0.2 to about 5 times the weight of the carrier particles; blending the mortar composition with water to produce a wetted mortar composition; and establishing physical contact between the wetted mortar composition and an article composed of a polymer plastic material at conditions effective for curing of the mortar 20 composition, thereby forming an improved adhesive bond between the mortar composition and the article.

2. The process of claim I in which the surfactant is selected from the group consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof. 25

3. The process of claim 1 or claim 2 in which the surfactant is selected from the group consisting of alkyl sulfosuccinates that each have a total of about 16 to about 32 alkyl carbon atoms per molecule, salts of alkyl sulfosuccinates that each have a total of about 16 to about 32 alkyl carbon atoms per molecule, and mixtures thereof. 30

4. The process of any one of claims I to 3 in which the carrier particles have a mean 26 668630 1 (GHMolters) P93752AU.1 SMORRIS average particle size of about I to about 200 micrometers and a capacity for carrying an amount by weight of the surfactant that is about 0.5 to about 4 times the weight of the carrier particles.

5 5. The process of any one of claims I to 4 in which the carrier particles are composed of calcium carbonate and have a specific surface area of about 0.1 to about 15 square meters per gram.

6. The process of any one of claims I to 5 in which the surfactant is about 35 to about 10 75 weight percent, based on the total weight of the surfactant composition.

7. The process of any one of claim I to 6 in which the surfactant is about 45 to about 75 weight percent, based on the total weight of the surfactant composition. 15

8. The process of any one of claims I to 7 in which the surfactant is present at an active-use level in the range of about 0.1 to about I weight percent.

9. The process of any one of claims I to 8 in which the conditions effective for curing of the mortar composition include maintaining the mortar at a temperature warmer than 32 20 degrees F. (0 degrees C.) for a period of about I to about 30 days.

10. The process of any one of claims 1 to 9 in which the surfactant composition also includes about I to about 10 weight percent of an anticaking agent. 25

11. An adhesive bond formed by the process of any one of claims 1-10.

12. A process for deaerating a mixture that includes mineral mortar, water and air, which process comprises: mixing a surfactant composition with mineral mortar, water and air at an active use 30 level of about 0.0 1 weight percent to about 0.5 weight percent; which solid surfactant composition includes 27 686306Q (GHMahers} P93752AU 1 SMORRIS a) about 30 to about 75 weight percent of a surfactant selected from the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures thereof; and b) carrier particles composed of an absorbent material selected from the group 5 consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; which carrier particles have a mean average particle size of about 0. 1 to about 1000 micrometers and a capacity for carrying an amount by weight of the surfactant that is about 0.2 to about 5 times the weight of the carrier particles. 10

13. The process of claim 12 in which the surfactant is selected from the group consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof.

14. The process of claim 12 or claim 13 in which the surfactant is selected from the group consisting of alkyl sulfosuccinates that each have a total of about 16 to about 32 15 alkyl carbon atoms per molecule, salts of alkyl sulfosuccinates that each have a total of about 16 to about 32 alkyl carbon atoms per molecule, and mixtures thereof.

15. The process of any one of claims 12 to 14 in which the carrier particles have a mean average particle size of about I to about 200 micrometers and a capacity for carrying an 20 amount by weight of the surfactant that is about 0.5 to about 4 times the weight of the carrier particles.

16. The process of any one of claims 12 to 15 in which the carrier particles are composed of calcium carbonate and have a specific surface area of about 0.1 to about 15 25 square meters per gram.

17. The process of any one of claims 12 to 16 in which the surfactant is about 35 to about 75 weight percent, based on the total weight of the surfactant composition. 30

18. The process of any one of claims 12 to 17 in which the surfactant is about 45 to about 75 weight percent, based on the total weight of the surfactant composition. 28 66OO3 _1 (GHMallers) P93752AU.1 SMORRIS

19. The process of any one of claims 12 to 18 in which the surfactant is a diisooctyl sulfosuccinate salt. 5

20. The process of any one of claims 12 to 19 in which the surfactant composition also includes about I to about 10 weight percent of an anticaking agent.

21. A free-flowing solid surfactant composition comprising: a) a surfactant selected from the group consisting of alkyl sulfosuccinates, salts 10 of alkyl sulfosuccinates, and mixtures thereof; and b) carrier particles composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin, and mixtures thereof; which carrier particles have a mean average particle size of about 0.1 to about 1000 micrometers and a capacity for carrying an amount by weight of the surfactant that is 15 about 0.2 to about 5 times the weight of the carrier particles.

22. The surfactant composition of claim 21 in which the surfactant is selected from the group consisting of alkyl sulfosuccinates that each have a total of about 16 to about 32 alkyl carbon atoms per molecule, salts of alkyl sulfosuccinates that each have a total of 20 about 16 to about 32 alkyl carbon atoms per molecule, and mixtures thereof.

23. The surfactant composition of claim 21 in which the surfactant is selected from the group consisting of consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof. 25

24. The surfactant composition of claim 23 in which the surfactant is selected from the group consisting of consisting of dioctyl sulfosuccinates, dioctyl sodium sulfosuccinates, dioctyl ammonium sulfosuccinates, didecyl sulfosuccinates, didecyl sodium sulfosuccinates, didecyl ammonium sulfosuccinates, and mixtures thereof. 30

25. The surfactant composition of claim 21 which does not comprise sodium benzoate. 29 6486306_1 (GHMatters) P93752AU 1 SMORRIS

26. The surfactant composition of claim 21 in which the carrier particles have a mean average particle size of about I to about 200 micrometers and a capacity for carrying an amount by weight of the surfactant that is about 0,5 to about 4 times the weight of the carrier particles. 5

27. The surfactant composition of claim 21 in which the carrier particles are composed of calcium carbonate and have a specific surface area of about 0.1 to about 15 square meters per gram. 10

28. The surfactant composition of claim 21 in which, based on the total weight of the surfactant composition, a) the surfactant is about 30 to about 75 weight percent, and is selected from the group consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof; 1 5 b) the carrier particles are about 10 to about 75 weight percent, which carrier particles have a mean average particle size of about 10 to about 160 micrometers and a capacity to absorb an amount by weight of the surfactant that is about 0.2 to about 4 times the weight of the carrier particles; and c) the surfactant composition includes an anticaking agent, and the anticaking agent 20 is about I to about 10 weight percent.

29. The composition of claim 28, in which the anticaking agent is composed of that hydrophobic silicon dioxide. 25

30. A dry-mix mortar composition that includes the surfactant composition of claim 26 and a dry-mix mortar.

31. The dry-mix composition of claim 30 in which the surfactant is selected from the group consisting of dialkyl sulfosuccinates that each have a total of about 16 to about 32 30 alkyl carbon atoms per molecule, salts of dialkyl sulfosuccinates that each have a total of about 16 to about 32 alkyl carbon atoms per molecule, and mixtures thereof. 30 6M88 _1 (GHMners) P93752AU.1 SMORRIS

32. The composition of claim 31 in which the surfactant is about 0.1 to about 1 wt%, based on the total weight of the dry-mix composition.

33. A process for manufacturing the surfactant composition of claim 1, which process 5 comprises: introducing into an absorption zone a surfactant selected from the group consisting of alkyl sulfosuccinates, salts of alkyl sulfosuccinates, and mixtures thereof; introducing into the absorption zone carrier particles composed of an absorbent material selected from the group consisting of calcium carbonate, calcium silicate, silicon 10 dioxide, kaolin, and mixtures thereof; which carrier particle have a mean average particle size of about 0.1 to about 1000 micrometers and a capacity for carrying an amount by weight of the surfactant that is about 0.2 to about 5 times the weight of the carrier particles; and maintaining the surfactant and the carrier particles in the absorption zone at 15 conditions effective for absorption of the surfactant by the carrier particles to produce the surfactant composition of claim 1.

34. The process of claim 33 which includes introducing into the absorption zone an anticaking agent. 20

35. The process of claim 34 in which the effective conditions include mixing, kneading, agitating or spray-drying the surfactant and the carrier particles.

36. The process of claim 35 in which the effective conditions include spray-drying the 25 surfactant and the carrier particles.

37. The process of claim 35 in which the anticaking agent is hydrophobic silicon dioxide. 30

38. The process of claim 35 which includes concentrating the liquid by vacuum drying or rotary evaporator drying. 31

6686306.1 (GHMuiers} P93752 AU.1 SMORRiS

39. The process of claim 35 which includes blending a defoamer with the solid surfactant composition and/or the carrier particles,

40. The process of claim 35 which includes blending a non-ionic surfactant with the 5 surfactant composition and/or the absorbent particles.

41. The use of the surfactant composition of claim 21 for forming an improved adhesive bond between a mortar and an article composed of a polymer plastic material. 10

42. The use of claim 41, in which the article is composed of expanded polystyrene or extruded polystyrene. 32 66863061 (GHMalters) P83762AU I SMORRIS