NZ611524B2 - Adhesive strength enhancers for cementitious compositions - Google Patents
Adhesive strength enhancers for cementitious compositions Download PDFInfo
- Publication number
- NZ611524B2 NZ611524B2 NZ611524A NZ61152412A NZ611524B2 NZ 611524 B2 NZ611524 B2 NZ 611524B2 NZ 611524 A NZ611524 A NZ 611524A NZ 61152412 A NZ61152412 A NZ 61152412A NZ 611524 B2 NZ611524 B2 NZ 611524B2
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- New Zealand
- Prior art keywords
- surfactant
- composition
- carrier particles
- sulfosuccinates
- weight
- Prior art date
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- 239000000203 mixture Substances 0.000 title claims abstract description 165
- 239000000853 adhesive Substances 0.000 title claims abstract description 38
- 230000001070 adhesive Effects 0.000 title claims abstract description 38
- 239000003623 enhancer Substances 0.000 title description 29
- 230000002708 enhancing Effects 0.000 title description 29
- 239000002245 particle Substances 0.000 claims abstract description 123
- 239000004094 surface-active agent Substances 0.000 claims abstract description 109
- 239000007787 solid Substances 0.000 claims abstract description 95
- 239000004570 mortar (masonry) Substances 0.000 claims abstract description 83
- 239000000969 carrier Substances 0.000 claims abstract description 75
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 46
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 23
- -1 alkyl sulfosuccinates Chemical class 0.000 claims abstract description 22
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 21
- 150000003839 salts Chemical class 0.000 claims abstract description 20
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 20
- 235000012239 silicon dioxide Nutrition 0.000 claims abstract description 20
- 239000011780 sodium chloride Substances 0.000 claims abstract description 20
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 15
- PZZYQPZGQPZBDN-UHFFFAOYSA-N Aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 claims abstract description 15
- 230000002745 absorbent Effects 0.000 claims abstract description 15
- 239000002250 absorbent Substances 0.000 claims abstract description 15
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 15
- JHLNERQLKQQLRZ-UHFFFAOYSA-N Calcium silicate Chemical compound [Ca+2].[Ca+2].[O-][Si]([O-])([O-])[O-] JHLNERQLKQQLRZ-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000000378 calcium silicate Substances 0.000 claims abstract description 13
- 229910052918 calcium silicate Inorganic materials 0.000 claims abstract description 13
- 235000012241 calcium silicate Nutrition 0.000 claims abstract description 13
- 229960003563 Calcium Carbonate Drugs 0.000 claims abstract description 12
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 12
- 239000004033 plastic Substances 0.000 claims abstract description 12
- 229920000642 polymer Polymers 0.000 claims abstract description 11
- 235000010216 calcium carbonate Nutrition 0.000 claims abstract description 9
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- ULUAUXLGCMPNKK-UHFFFAOYSA-L 2-sulfobutanedioate Chemical class OS(=O)(=O)C(C([O-])=O)CC([O-])=O ULUAUXLGCMPNKK-UHFFFAOYSA-L 0.000 claims description 73
- 238000000034 method Methods 0.000 claims description 57
- 239000004793 Polystyrene Substances 0.000 claims description 27
- 229920002223 polystyrene Polymers 0.000 claims description 27
- 238000010521 absorption reaction Methods 0.000 claims description 23
- 238000001694 spray drying Methods 0.000 claims description 19
- 238000002156 mixing Methods 0.000 claims description 15
- 230000002209 hydrophobic Effects 0.000 claims description 10
- OXLXSOPFNVKUMU-UHFFFAOYSA-N 1,4-dioctoxy-1,4-dioxobutane-2-sulfonic acid Chemical class CCCCCCCCOC(=O)CC(S(O)(=O)=O)C(=O)OCCCCCCCC OXLXSOPFNVKUMU-UHFFFAOYSA-N 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 6
- WXMKPNITSTVMEF-UHFFFAOYSA-M Sodium benzoate Chemical compound [Na+].[O-]C(=O)C1=CC=CC=C1 WXMKPNITSTVMEF-UHFFFAOYSA-M 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 5
- 239000004794 expanded polystyrene Substances 0.000 claims description 5
- 235000010234 sodium benzoate Nutrition 0.000 claims description 5
- 239000004299 sodium benzoate Substances 0.000 claims description 5
- 238000004898 kneading Methods 0.000 claims description 4
- 239000002736 nonionic surfactant Substances 0.000 claims description 4
- HWJHLQSSWFHRQU-UHFFFAOYSA-N 1,4-didecoxy-1,4-dioxobutane-2-sulfonic acid Chemical class CCCCCCCCCCOC(=O)CC(S(O)(=O)=O)C(=O)OCCCCCCCCCC HWJHLQSSWFHRQU-UHFFFAOYSA-N 0.000 claims description 3
- 238000001291 vacuum drying Methods 0.000 claims description 2
- 235000019329 dioctyl sodium sulphosuccinate Nutrition 0.000 claims 1
- GIEOZKHHGLDNRY-UHFFFAOYSA-N dioctylazanium;2-sulfobutanedioate Chemical class OS(=O)(=O)C(C([O-])=O)CC([O-])=O.CCCCCCCC[NH2+]CCCCCCCC.CCCCCCCC[NH2+]CCCCCCCC GIEOZKHHGLDNRY-UHFFFAOYSA-N 0.000 claims 1
- HNSDLXPSAYFUHK-UHFFFAOYSA-N 1,4-bis(2-ethylhexyl) sulfosuccinate Chemical compound CCCCC(CC)COC(=O)CC(S(O)(=O)=O)C(=O)OCC(CC)CCCC HNSDLXPSAYFUHK-UHFFFAOYSA-N 0.000 description 38
- 229910052500 inorganic mineral Inorganic materials 0.000 description 25
- 239000011707 mineral Substances 0.000 description 25
- 239000004568 cement Substances 0.000 description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 14
- 239000000243 solution Substances 0.000 description 13
- 239000004615 ingredient Substances 0.000 description 12
- 239000012266 salt solution Substances 0.000 description 11
- JMGZBMRVDHKMKB-UHFFFAOYSA-L disodium;2-sulfobutanedioate Chemical compound [Na+].[Na+].OS(=O)(=O)C(C([O-])=O)CC([O-])=O JMGZBMRVDHKMKB-UHFFFAOYSA-L 0.000 description 8
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Inorganic materials [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 8
- 239000011734 sodium Substances 0.000 description 8
- 229910052708 sodium Inorganic materials 0.000 description 8
- 238000009472 formulation Methods 0.000 description 7
- 150000003385 sodium Chemical group 0.000 description 7
- QGZKDVFQNNGYKY-UHFFFAOYSA-O ammonium group Chemical group [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 6
- 239000000945 filler Substances 0.000 description 6
- 238000009413 insulation Methods 0.000 description 6
- 239000006193 liquid solution Substances 0.000 description 6
- 239000011404 masonry cement Substances 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 239000002904 solvent Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- LKCWBDHBTVXHDL-RMDFUYIESA-N Amikacin Chemical compound O([C@@H]1[C@@H](N)C[C@H]([C@@H]([C@H]1O)O[C@@H]1[C@@H]([C@@H](N)[C@H](O)[C@@H](CO)O1)O)NC(=O)[C@@H](O)CCN)[C@H]1O[C@H](CN)[C@@H](O)[C@H](O)[C@H]1O LKCWBDHBTVXHDL-RMDFUYIESA-N 0.000 description 4
- 239000001692 EU approved anti-caking agent Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 239000002518 antifoaming agent Substances 0.000 description 4
- NHNBRUZMOBULPD-UHFFFAOYSA-N azanium;4-hydroxy-4-oxo-3-sulfobutanoate Chemical compound N.OC(=O)CC(C(O)=O)S(O)(=O)=O NHNBRUZMOBULPD-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 229910004762 CaSiO Inorganic materials 0.000 description 3
- 229940088417 PRECIPITATED CALCIUM CARBONATE Drugs 0.000 description 3
- 239000011398 Portland cement Substances 0.000 description 3
- 125000000217 alkyl group Chemical class 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000010440 gypsum Substances 0.000 description 3
- 229910052602 gypsum Inorganic materials 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 239000008247 solid mixture Substances 0.000 description 3
- 229910002012 Aerosil® Inorganic materials 0.000 description 2
- 230000000996 additive Effects 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- 125000000129 anionic group Chemical group 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000011449 brick Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 230000001737 promoting Effects 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 241000219430 Betula pendula Species 0.000 description 1
- 229960005069 Calcium Drugs 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L Calcium stearate Chemical class [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 206010015946 Eye irritation Diseases 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 210000000282 Nails Anatomy 0.000 description 1
- 241000590428 Panacea Species 0.000 description 1
- 206010040880 Skin irritation Diseases 0.000 description 1
- 241000244040 Terranova Species 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 150000003863 ammonium salts Chemical class 0.000 description 1
- 125000004429 atoms Chemical group 0.000 description 1
- 235000012216 bentonite Nutrition 0.000 description 1
- 230000027455 binding Effects 0.000 description 1
- 235000012970 cakes Nutrition 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 125000004432 carbon atoms Chemical group C* 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- AEVBUGHMKXBGBL-UHFFFAOYSA-N didecyl butanedioate Chemical compound CCCCCCCCCCOC(=O)CCC(=O)OCCCCCCCCCC AEVBUGHMKXBGBL-UHFFFAOYSA-N 0.000 description 1
- KWABLUYIOFEZOY-UHFFFAOYSA-N dioctyl butanedioate Chemical compound CCCCCCCCOC(=O)CCC(=O)OCCCCCCCC KWABLUYIOFEZOY-UHFFFAOYSA-N 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 231100000013 eye irritation Toxicity 0.000 description 1
- 239000000789 fastener Substances 0.000 description 1
- 230000002349 favourable Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 230000005661 hydrophobic surface Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000003446 ligand Substances 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 235000012245 magnesium oxide Nutrition 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000002085 persistent Effects 0.000 description 1
- 239000011505 plaster Substances 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 231100000475 skin irritation Toxicity 0.000 description 1
- KEAYESYHFKHZAL-UHFFFAOYSA-N sodium Chemical compound [Na] KEAYESYHFKHZAL-UHFFFAOYSA-N 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
Abstract
Disclosed is a free-flowing solid surface composition comprising a surfactant selected from the group consisting of a) 30 - 75 weight percent 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. The carrier particles have a mean average particle size of about 0.1 to about 1000 micrometres and a capacity for carrying an amount by weight of the surfactant that is 0.2 to 5 times the weight of the carrier. The composition may further contain an anticaking agent and may be part of a mortar dry mix. The disclosure also relates to the method of manufacture of the composition and the use of it for forming an adhesive bond between a mortar and an article composed of a polymer plastic material. up consisting of calcium carbonate, calcium silicate, silicon dioxide, kaolin and mixtures thereof. The carrier particles have a mean average particle size of about 0.1 to about 1000 micrometres and a capacity for carrying an amount by weight of the surfactant that is 0.2 to 5 times the weight of the carrier. The composition may further contain an anticaking agent and may be part of a mortar dry mix. The disclosure also relates to the method of manufacture of the composition and the use of it for forming an adhesive bond between a mortar and an article composed of a polymer plastic material.
Description
ADHESIVE STRENGTH ENHANCERS
FOR CEMENTITIOUS COMPOSITIONS
Background of the Invention
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.
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 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
long 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,
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 “EIFS” means any one of a number of
unique proprietary systems, each of which may consist of specific components
associated with a particular EIFS producer. One basic type of EIFS, known as “barrier
EIFS”, includes boardstock insulation, reinforced adhesive, and exterior coating
arranged in three layers. A less common type of EIFS, known as “drainage EIFS”, 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 EIFS construction is creating a durable and
economical adhesive bond between masonry mortar and polystyrene.
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 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 filler layer to the outer face of the polystyrene
boardstock, and 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 for the topcoat. Available textures include smooth surfaces,
rough stucco-like textures, embedded stone chips, granite-like mixtures and brick-like
treatments.
U.S. Patent No. 6,172,147, 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 (referred to collectively in the ‘147 patent as “AEAs”) as suitable for
use in the masonry mortar additive. Among these, listed at Column 4, lines 3-5 of the
‘147 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).
U.S. 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 entraining agent (referred to
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
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 ‘099 patent compositions is that sodium benzoate absorbs water in
humid atmospheres, and caking and clumping may be expected if the ambient humidity
exceeds 50%. Another objection to the ‘099 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. It is an object of the present
invention to go some way towards meeting this need; and/or to at least provide the
public with a useful choice. Preferably, the new solid surfactant 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 cements and mortars.
SUMMARY OF THE INVENTION
It has now 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 adhesion enhancers 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 compositions. Processes for preparing and using the free-
flowing, solid adhesion enhancers are described below.
In one aspect, the invention is a free-flowing solid surfactant composition that
includes about 30 to about 75 weight percent of 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 material selected from calcium carbonate, calcium silicate, silicon 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 about 0.2 to about 5 times the weight of the carrier particles.
In another aspect, the invention is a free-flowing solid surfactant composition
that includes about 30 to about 75 weight percent of a surfactant composed of dialkyl
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 average particle size of about 10 to 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 1
to about 10 weight percent of an anticaking agent.
In yet another aspect, the invention is a dry-mix mortar composition including a
dry-mix mortar and a solid surfactant composition as described above, wherein the
carrier particles have a mean average particle size of about 1 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.
In yet another aspect, the invention is 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 is also a process for manufacturing a free-flowing solid surfactant
composition of the invention. The process includes introducing a surfactant selected
from 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 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. 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 composition.
In still another aspect, the invention is 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 surfactant composition. A defoamer, a non-ionic surfactant, or both
maybe blended with liquid solution.
The invention is also 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 composition as
described above, and establishing and maintaining physical contact between the cement
composition and an article composed of a polymer plastic material at conditions
effective for curing of the mortar composition.
The invention provides an adhesive strength enhancer for hydraulic setting
materials. For example, 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.
The invention also provides the use of a free-flowing solid surfactant
composition of the invention for forming an improved adhesive bond between a mortar
and an article composed of a polymer plastic material.
In the description in this specification reference may be made to subject matter
which is not within the scope of the appended claims. That subject matter should be
readily identifiable by a person skilled in the art and may assist in putting into practice
the invention as defined in the appended claims.
DETAILED DESCRIPTION OF
PREFERRED ASPECTS OF THE INVENTION
In a preferred embodiment, the invention is a free-flowing solid surfactant
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 a job 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 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.
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 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 1 to
about 200 micrometers, most preferably about 10 to 160 micrometers. A typical
preferred particle size distribution includes 50% of particle below 4 micrometers, 95%
of particles below 26 micrometers, and 100% of particles below 56 micrometers.
Carrier particles less than 1 micrometer are not recommended for use in the
invention because they cause dusting problems and are sometimes associated with risks
to human health. Also, these extremely small 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
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 1 to about 4 times the weight of the carrier particles,
most preferably about 1 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 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 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. 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 gram. Suitable silicon dioxide particles in this size
range usually have 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.
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 them water repellent.
Examples of 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 1 to about 10
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 above; carrier particles as described above; and an anticaking agent as
described above. Preferably the solid surfactant composition includes about 0.1 to
about 1 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.
The inventors have discovered that the presence of about 0.1 to about 1 wt%,
dioctyl sulfosuccinates, didecyl sulfosuccinates, 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 dioctyl sulfosuccinates, no didecyl sulfosuccinates, 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 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.
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 1000 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 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, 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.
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 absorption of the solution into the carrier particles and warm
enough to evaporate the 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. 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 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 all of
the solvent from the particles.
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.
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 conditions effective for curing the mortar composition include
maintaining a temperature warmer than 32 degrees F. for a period of about 1 to about 30
days. The conditions effective for curing of the mortar composition are well known to
practitioners in the field of cement and mortar formulation.
The following examples are presented to better communicate the invention, and
are not meant to limit the invention in any way. Unless otherwise indicated, all
references to parts, percentages or proportions are based on weight.
Examples
Preparative Example 1: Spray-Drying Sulfosuccinate Salt Solution with Particles
The following procedure (hereinafter referred to as “Procedure 1”) is performed
for preparing solid formulations of the invention. An aqueous dialkyl sulfosuccinate
salt solution is spray dried with carrier particles and/or anti-caking particle in a fluidized
bed to produce a free-flowing solid formulation with good caking resistance. For the
present 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 well-known to practitioners in the art of spray-drying. Table 1, below,
summarizes the sulfosuccinate salts and particles introduced into the fluidized bed spray
drier for specific procedures 1a through 1e, based on the mass of the solid formulations
produced by the procedure.
TABLE 1: Preparation of Strength Enhancer by Spray-Drying Solution with Particles
Procedure Active Active CaCO SiO Comments
No. Ingredient Ingredient Particles Particles
(chemical (mass% (mass% of (mass% of
name) of product product) product)
1a Diisodecyl 37.7 mass% 54.5 mass% 7.8 mass% Product is a
ammonium free-flowing
sulfosuccinate solid of the
INVENTION
1b Diisodecyl 38.5 mass% 57.0 mass% 4.5 mass% Product is a
ammonium free-flowing
sulfosuccinate solid of the
INVENTION
1c Diisooctyl 45.1 mass% 51.2 mass% 3.7 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
INVENTION
1d Diisooctyl 31.8 mass% 64.8 mass% 3.4 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
INVENTION
1e Diisooctyl 53.0 mass% 43.7 mass% 3.3 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
INVENTION
Legend: * precipitated calcium carbonate particulate commercially available
from Omya Hamburg GmbH of Hamburg, Germany under the
tradename Omyacarb
+ hydrophobic precipitated silicon dioxide particulate commercially
available from Evonik Degussa Corporation of Wesseling, Germany
under the tradename Sipernat
The data of Table 1 above demonstrates that free-flowing, solid formulations of
the invention can be produced by spray-drying an aqueous dialkyl sulfosuccinate salt
solution with carrier particles and/or anti-caking particles in a fluidized bed.
Preparative Example 2: Admixing Sulfosuccinate Salt Solution with Particles
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 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 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
Procedure Active Active CaSiO SiO 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
ammonium contains 25%
sulfosuccinate solvent and is
(50%) a free-flowing
solid of the
INVENTION
2b Diisodecyl 30 mass% 0 mass% 50 mass% Product
ammonium contains 20%
sulfosuccinate solvent and is
(60%) a free-flowing
solid of the
INVENTION
2c Diisooctyl 40 mass% 42 mass% 0 mass% Product
sodium contains 18%
sulfosuccinate solvent and is
(70%) a free-flowing
solid of the
INVENTION
Legend: * precipitated calcium silicate particulate commercially available from
J.M. 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 admixing an aqueous dialkyl sulfosuccinate salt
solution in liquid for with absorbent carrier particles and/or absorbent anti-caking
particles.
Preparative Example 3: Blending Dried Dialkyl Sulfosuccinate 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 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 added to the contents of the mixer in order to modify the physical or
chemical properties of the solid formulation. Table 3, below, summarizes the dried
dialkyl sulfosuccinate salts, the particles, the additional ingredients (if any), and the
solid formulations produced by specific procedures.
TABLE 3: Preparation of Strength Enhancer by Blending Dried Salt with Particles
~ * +
Active Kaolin CaCO SiO Comments
Procedure Ingredient Particles Particles Particles
No. / (mass% (mass% (mass% of (mass% of
of product) of product) product) product)
3b Diisodecyl 0 mass% 34 mass% 0 mass% Product is a
ammonium free-flowing
sulfosuccinate solid of the
/ 66 mass% INVENTION
3c Diisodecyl 0 mass% 55 mass% 8 mass% Product is a
ammonium free-flowing
sulfosuccinate solid of the
/ 37 mass% INVENTION
3d Diisooctyl 0 mass% 0 mass% 50 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
/ 50 mass% INVENTION
3e Diisooctyl 0 mass% 34 mass% 0 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
/ 66 mass% INVENTION
3f Diisooctyl 0 mass% 35 mass% 5 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
60 mass% INVENTION
3g Diisooctyl 50 mass% 0 mass% 0 mass% Product is a
sodium free-flowing
sulfosuccinate solid of the
/ 50 mass% INVENTION
Legend: ~ hydrated aluminium silicate particulate commercially available from
KaMin LLC of Macon, Georgia, U.S.A. under the tradename
KaMin 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 Degussa Corporation of
Wesseling, Germany under the tradenames Sipernat and Aerosil
The data of Table 3 above demonstrates that free-flowing, solid formulations of
the invention can be produced by blending a dried dialkyl sulfosuccinate salt solution in
solid form with carrier particles and/or anti-caking particles.
Performance Example 4: Testing of Spray-Dried Adhesive Bond Strength Enhancers
The following performance testing procedure (hereinafter referred to as “the
Testing Procedure”) is performed in order to determine the effect of an 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 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”) ” and “BAUMIT
Adhesivefiller Allround (“Klebespachtel Allround”) ”, which are commercially
available from Baumit. The mineral mortar is added to water in a ratio of 4 to 1 and
mixed for one minute. In each trial, an active concentration use level of 0.3 to 0.6
mass% dialkyl sulfosuccinate 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 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 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 various spray-dried dialkyl sulfosuccinate salts and presented in Table 4, below.
TABLE 4: Adhesion Increase for Spray-Dried Dialkyl Sulfosuccinate Salts
in Mineral Mortar on Polystyrene Boards
Test Strength Mineral Mortar XPS or EPS Dry Active Adhesion
No. Enhancer Product Name (Producer/ Time Use- Increase
(active content (Producer) Board Name) Level (percent)
of solid form)
4a DDSS Klebespachtel XPS 28 0.5% + 42 %
(38%) Allround (BASF/ days
(Baumit ) 3035 CS)
4b DOSS Klebespachtel XPS 28 0.5% + 48 %
(45%) Allround (BASF/ days
(Baumit) 3035 CS)
4c DOSS Klebespachtel XPS 14 0.5% + 65 %
(45%) Allround (Dow/Austro days
(Baumit) therm Top P)
4d DOSS STOlevell Uni EPS 28 0.4%- + 44 %
(45%) (Sto ) (Sto/ days 0.5%
PS30SE)
4e DOSS STOlevell Uni XPS 28 0.4% + 78 %
(45%) (Sto) (BASF/ days
3035 CS)
4f DOSS Capatect XPS 28 0.5% + 58 %
(45%) (DAW ) (BASF/ 3035 days
4g DOSS Combi Putz 499 EPS 7 0.5% + 11 %
(45%) (Greutol ) (Greutol) days
4h DOSS Combi Putz 499 XPS 7 0.5% + 34 %
(45%) (Greutol) (BASF/ days
3035 CS)
4i DOSS Klebespachtel XPS 7 0.5% + 9 %
(45%) (Quarzolith ) (BASF/ days
3035 CS)
4k DOSS Klebespachtel XPS 28 0.3% + 30 %
(45%) (St. Gobain ) (Weber- days
Terranova)
4l DOSS WDVS XPS 14 0.5% + 62 %
(45%) Pulverkleber (BASF/ days
3550 (Brillux ) 3035 CS)
4m DOSS Klebemörtel 804 XPS 14 0.6% + 54 %
(45%) (Hasit ) (BASF/ days
3035 CS)
Legend: 1 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 diisodecyl 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% active content, produced by the spray-drying process described
above in Example 1.
4 Baumit means Wietersdorfer & Peggauer Zementwerke GmbH,
A-9373 Klein, St. Paul
Sto means STO AG, Ehrenbachstraße, 1 D-79780 Stühlingen
6 DAW means Synthesa Chemie Ges.m.b.H, Dirnbergerstraße 29-
31, A-4320 Perg
7 Greutol means Greutol AG, Libernstraße 28, CH-8112 Otelfingen
8 Quarzolith means Quarzolith Süd GmbH, Mitterdorferstraße 1,
A-8572 Bärnbach
9 St. Gobain means Saint Gobain, Weber Maxit, Gleichentheilgasse
6, A-1230 Wien
Brillux means Brillux GmbH & Co. KG, Weseler Straße 401,
D-48163 Münster
11 Hasit means Hasit Trockenmörtel GmbH, Karl-Knab-Straße 44,
D-92521 Schwarzenfeld
Inspection of Table 4 above reveals that diisodecyl sodium sulfosuccinate in
solid form of 38% active content, and diisooctyl sodium sulfosuccinate in solid form of
45% active content, produced by the spray-drying process described above in Example
1 significantly increase the strength of an adhesive bond between a polystyrene board
and a variety of commercially available mineral mortar products.
Performance Example 5: Testing of Spray-Dried Adhesive Bond Strength Enhancers
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 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
aqueous solution of dioctyl sulfosuccinate salt with a calcium carbonate carrier is pre-
mixed for about a minute with a dry-mix, hydraulically-setting, cementitious mineral
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 of 4 to 1 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 utilized.
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 mortar test specimens 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 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 a various use-levels of a particular spray-dried dioctyl sulfosuccinate salt in a certain
mineral mortar on identical polystyrene boards and presented in Table 5, below.
TABLE 5: Adhesion Increase for Various Use-Levels of Spray-Dried Dioctyl
Sulfosuccinate Salt in a Mineral Mortar on a Polystyrene 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 Klebespachtel XPS 7 0.1% + 4 %
(45%) Allround (Dow /Austro- days
(Baumit ) therm Top P)
5b DOSS Klebespachtel XPS 7 0.2% + 38 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5c DOSS Klebespachtel XPS 7 0.3% + 44 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5d DOSS Klebespachtel XPS 7 0.4% + 46 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5e DOSS Klebespachtel XPS 7 0.5% + 51 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5f DOSS Klebespachtel XPS 7 0.6% + 43 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5g DOSS Klebespachtel XPS 7 0.7% + 35 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
5h DOSS Klebespachtel XPS 7 0.8% + 22 %
(45%) Allround (Dow/Austro- days
(Baumit) therm Top P)
Legend: 1 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% active content, produced by the spray-drying process described
above in Example 1.
3 Baumit means Wietersdorfer & Peggauer Zementwerke GmbH,
A-9373 Klein, St. Paul
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 1 mass% active use-level.
Performance Example 6: Performance Testing of Admixed Bond Strength Enhancers
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 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
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)
Particles
6a DDSS Klebespachtel XPS 7 0.5% + 27%
(25%) / Allround (BASF/ days
SiO (Baumit ) 3035 CS)
6b DDSS Klebespachtel XPS 28 0.5% + 32%
(25%) / Allround (BASF/ days
SiO (Baumit) 3035 CS)
6c DDSS Klebespachtel XPS 7 0.5% + 26%
(30%) / Allround (BASF/ days
SiO (Baumit) 3035 CS)
6d DDSS Klebespachtel XPS 28 0.5% + 28%
(30%) / Allround (BASF/ days
SiO (Baumit) 3035 CS)
6e DOSS Klebespachtel XPS 14 0.5% + 10%
(40%) / CaSiO * Allround (BASF/ days
(Baumit ) 3035 CS)
6f DOSS Klebespachtel XPS 14 0.6% + 35%
(40%) / CaSiO * Allround (BASF/ days
(Baumit) 3035 CS)
Legend: 1 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 diisodecyl ammonium sulfosuccinate in solid form,
of 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.
4 Baumit 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 Sipernat
* precipitated calcium silicate particulate commercially available
from J.M. 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 increases the strength of an adhesive bond between a polystyrene board
and a commercially available mineral mortar product.
Performance Example 7: Testing of Dried Sulfosuccinate Salts Blended with
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. Adhesion enhancement values are determined for the dried dialkyl
sulfosuccinate salts with solid carrier materials in accordance with the Testing
Procedure, as set forth above in Example 6. In each trial, an active concentration of 0.5
mass% dried dialkyl sulfosuccinate salt is utilized. The resulting adhesion enhancement
values are presented in Table 7 below.
TABLE 7: Adhesion Increase for Dried Dialkyl Sulfosuccinate Salt with
Particles 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)
Particle
(mass%)
7a DDSS Klebespachtel XPS 7 0.5% + 37%
(66%) / Allround (BASF/ days
CaCO (Baumit ) 3035 CS)
(34%)
DDSS Klebespachtel XPS 28 0.5% + 30%
(66%) / Allround (BASF/ days
CaCO (Baumit) 3035 CS)
(34%)
DOSS Klebespachtel XPS 7 0.5% + 49%
(66%) / Allround (BASF/ days
CaCO (Baumit) 3035 CS)
(34%)
DOSS Klebespachtel XPS 28 0.5% + 37%
(66%) / Allround (BASF/ days
CaCO (Baumit) 3035 CS)
(34%)
DOSS Klebespachtel XPS 7 0.5% + 23%
(50%) / Allround (BASF/ days
Kaolin clay (Baumit) 3035 CS)
(50%)
DOSS Klebespachtel XPS 7 0.5% + 16%
(50%) / Allround (BASF/ days
SiO (Baumit) 3035 CS)
(50%)
Legend: 1 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 diisodecyl ammonium sulfosuccinate in solid form,
produced by blending dried diisodecyl ammonium sulfosuccinate with
particulate as described above in Example 3.
3 DOSS means diisooctyl sodium sulfosuccinate in solid form,
produced by blending dried diisooctyl sodium sulfosuccinate with
particulate as described above in Example 3.
4 Baumit means Wietersdorfer & Peggauer Zementwerke GmbH,
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 KaMin LLC of Macon, Georgia, U.S.A. under the
tradename KaMin
*** hydrophobic fumed silicon dioxide particulate commercially
available from Evonik Degussa Corporation of Wesseling,
Germany under the tradename Aerosil
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
product.
Performance Example 8: Deaerating Effect of Spray-Dried Dioctyl Sulfosuccinate Salt
A solid surfactant composition that contains 45% diisooctyl sulfosuccinate salt
prepared in accordance with Procedure 1, set forth above in Preparative Example 1. In
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 4:1, and the volume of the mixture is measured. The volumes are set
forth below in Table 8.
TABLE 8: Mineral Mortar Volume
Test Strength Mineral Mortar Active use- Volume
No. Enhancer Product Name level (milliters)
Active (Producer) (percent in
Ingredient mixture)
(mass%)
DOSS Klebespachtel 0.000% 61 ml
(45%) Allround (Control)
(Baumit )
DOSS Klebespachtel 0.010% 63 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.025% 54 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.050% 54 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.075% 53 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.100% 53 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.250% 52 ml
(45%) Allround
(Baumit)
DOSS Klebespachtel 0.500% 51 ml
(45%) Allround
(Baumit)
Legend: 1 DOSS means diisooctyl sodium sulfosuccinate in solid form, of
45% active content, produced by the spray-drying process described
above in Example 1.
2 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.
The term “comprising” as used in this specification and claims means
“consisting at least in part of”. When interpreting statements in this specification and
claims which include the term “comprising”, other features besides the features
prefaced by this term in each statement can also be present. Related terms such as
“comprise” and “comprised” are to be interpreted in similar manner.
In this specification where reference has been made to patent specifications,
other external documents, or other sources of information, this is generally for the
purpose of providing a context for discussing the features of the invention. Unless
specifically stated otherwise, reference to such external documents is not to be
construed as an admission that such documents, or such sources of information, in any
jurisdiction, are prior art, or form part of the common general knowledge in the art.
Claims (27)
1. A free-flowing solid surfactant composition comprising: a) about 30 to about 75 weight percent of a surfactant selected from the 5 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 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 10 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.
2. The surfactant composition of Claim 1 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 15 of about 16 to about 32 alkyl carbon atoms per molecule, and mixtures thereof.
3. The surfactant composition of Claim 1 in which the surfactant is selected from the group consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof.
4. The surfactant composition of Claim 3 in which the surfactant is selected from 20 the group consisting of dioctyl sulfosuccinates, dioctyl sodium sulfosuccinates, dioctyl ammonium sulfosuccinates, didecyl sulfosuccinates, didecyl sodium sulfosuccinates, didecyl ammonium sulfosuccinates, and mixtures thereof.
5. The surfactant composition of Claim 1 which does not comprise sodium benzoate. 25
6. The surfactant composition of Claim 1 in which the carrier particles have a mean average particle size of about 1 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.
7. The surfactant composition of Claim 1 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.
8. The surfactant composition of Claim 1 in which 5 a) the surfactant is selected from the group consisting of dialkyl sulfosuccinates, salts of dialkyl sulfosuccinates, and mixtures thereof; and in which, based on the total weight of the surfactant composition, 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 10 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 is about 1 to about 10 weight percent.
9. The composition of claim 8, in which the anticaking agent is composed of 15 hydrophobic silicon dioxide.
10. A dry-mix mortar composition that includes the surfactant composition of claim 6 and a dry-mix mortar.
11. The dry-mix composition of claim 10 in which the surfactant is selected from the group consisting of dialkyl sulfosuccinates that each have a total of about 16 to 20 about 32 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.
12. The composition of claim 11 in which the surfactant is about 0.1 to about 1 wt%, based on the total weight of the dry-mix composition. 25
13. A process for manufacturing the surfactant composition of claim 1, which process 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 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 5 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 conditions effective for absorption of the surfactant by the carrier particles to produce the surfactant composition of claim 1. 10
14. The process of claim 13 which includes introducing into the absorption zone an anticaking agent.
15. The process of claim 14 in which the effective conditions include mixing, kneading, agitating or spray-drying the surfactant and the carrier particles.
16. The process of claim 15 in which the effective conditions include spray-drying 15 the surfactant and the carrier particles.
17. The process of claim 15 in which the anticaking agent is hydrophobic silicon dioxide.
18. The process of claim 15 which includes concentrating the liquid by vacuum drying or rotary evaporator drying. 20
19. The process of claim 15 which includes blending a defoamer with the solid surfactant composition and/or the carrier particles,
20. The process of claim 15 which includes blending a non-ionic surfactant with the surfactant composition and/or the absorbent particles.
21. The use of the surfactant composition of claim 1 for forming an improved 25 adhesive bond between a mortar and an article composed of a polymer plastic material.
22. The use of claim 21, in which the article is composed of expanded polystyrene or extruded polystyrene.
23. A surfactant composition of any one of Claims 1 to 9 substantially as herein described with reference to any example thereof.
24. A dry-mix mortar composition of any one of Claims 10 to 12 substantially as herein described with reference to any example thereof. 5
25. A process of any one of Claims 13 to 20 substantially as herein described with reference to any example thereof.
26. The use of Claim 21 or 22 substantially as herein described with reference to any example thereof.
27. The surfactant composition of Claim 1 when manufactured by the process of 10 any one of Claims 13 to 20 and 25.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ611524A NZ611524B2 (en) | 2012-02-09 | Adhesive strength enhancers for cementitious compositions |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ611524A NZ611524B2 (en) | 2012-02-09 | Adhesive strength enhancers for cementitious compositions |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ611524A NZ611524A (en) | 2014-08-29 |
NZ611524B2 true NZ611524B2 (en) | 2014-12-02 |
Family
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