RU2575270C1 - Joint compound, wall structure and related methods and products - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: aspects of the invention are compositions of joint compounds, wall structures, methods to treat walls and products related to any of the above aspects, including a reinforcing pad, for example, to protect angles in the areas of slabs jointing, fixtures and a tape for joints covering. The composition of the joint compound of drying type includes (a) a binder selected from polymers of acrylic acid, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of the specified compounds, and (b) multiple hollow balls, besides, the specified balls have average isostatic compression strength at least 100 psi (689 kPa), measured according to ASTM D3102-78. The invention also relates to a wall structure, containing: (a) two adjacent boards connected with a joint, (b) a single layer of the specified joint compound composition in a joint to ensure uniform aesthetically attractive appearance and (c) a flat tape stable in size and not swelling to seal joints, included into the joint. Besides, the invention relates to the method to treat a wall structure, comprising two adjacent slabs, connected with a joint, which includes: a) application of a tape to cover joints and one layer of the specified composition of joint compound onto the joint and (b) drying of the composition. The joint compound is preferably a composition of drying type with reduced shrinkage, containing a binder and hollow balls, at the same time in some versions of realisation they as a result produce an ultralight composition. In preferable versions of realisation the joint compound composition may be applied in the form of single-layer treatment. Other aspects of slab finishing system include such single-layer treatment, as a result of which make it possible for a user to work with joint compound closer to the plane of the slab compared to regular compositions. In some versions of realisation the tape for covering of joints and the strengthening pad may include a lining material from a non-swelling synthetic paper.

EFFECT: reduced labour intensiveness and cheaper manufacturing, increased strength of heat insulating material surface adhesion.

15 cl, 48 dwg, 10 tbl

Description

CROSS RELATIONS TO RELATED APPLICATIONS

[0001] This patent application claims priority according to provisional application for US patent No. 61/705551, filed September 25, 2012, application for US patent No. 13/842342, filed March 15, 2013, and patent application US No. 14 / 034290, filed September 23, 2013, the contents of which are fully incorporated into this application by reference.

BACKGROUND

[0002] In construction, various types of cladding are used as panels to create the internal and external surfaces of walls and ceilings. For simplicity, in the present description it should be understood that the term "wall" also includes ceilings. Typically, claddings are in the form of slabs (also called panels) attached to carcass elements, such as structures of a wooden beam-post carcass, known in the art. Examples of cladding include gypsum boards lined with paper, fiber mats (e.g., fiberglass), and so on. These and other types of slabs are usually cut to the appropriate size and then attached to the frame elements, for example, with screws, nails or similar fasteners, forming wall sections formed by a plurality of slabs.

[0003] Such wall sections are usually finished to provide aesthetically beautiful, uniform and protected surfaces. For example, two slabs adjacent to one another, located in the same plane, will form a butt weld between themselves on vertical walls and horizontal ceilings. To finish the seam, a reinforcing tape for seams with a layer of suture sealant under the specified tape is placed in the seam, and many layers of suture sealant are applied over the tape. Some plates connect at an angle to form an angle. To hide the corner seam and protect the corner, a reinforcing pad can be used. The reinforcing pad can be directly attached to the plate using fasteners, or a layer of suture sealant is applied under the pad to adhere the reinforcing pad to the plate. Then the installed reinforcement is masked with many layers of suture sealant applied to the pad. The fasteners used to attach the plate to the frame elements also need to be masked with many layers of suture sealant applied to the specified fasteners. After the various applied suture sealants have dried, the resulting wall surfaces can be sanded and painted to obtain the desired uniform and aesthetically pleasing appearance.

[0004] The level of finish described above may vary. For example, for gypsum wallboards, six (6) levels of gypsum board finish are considered in the art, ranging from level zero (no finish at all) to level five (highest level of finish), as indicated in the Gypsum Production Association GA-214 document and C840 of the American Society for Testing and Materials ("ASTM"). Finishing levels generally correspond to the number of seam sealants applied to the seams, linings and fasteners. For areas of residence of people in buildings, levels three, four and five are usually used. For private homes, the most commonly used level is level 4. Level 5 is used less frequently, and it usually requires a coating layer over the joint sealant on the entire surface of the wall.

[0005] The conventional wall finishing approaches described above are not entirely satisfactory. The materials commonly used for finishing wall structures create significant inefficient moments in the method, and also require an advanced level of skill for effective use. For example, existing joint sealants require three separate coatings on the fasteners, as well as multiple coatings on flat joints between plates in the same plane, and fillet welds. Each coating must dry separately, which brings significant downtime to the construction process, in particular because builders of other professions usually cannot work inside the building while the walls are being finished. Each layer of joint sealant may take about a day to dry, and it usually takes about a week to install gypsum boards and finish flat joints, fasteners, and corner pieces in a typical new home design with a living area of 2,400 square feet (223 square meters) (corresponding to approximately 10,000 square feet (929 sq.m) plates).

[0006] In addition, the need to apply multiple layers of suture sealant requires the user to work with the suture sealant well above the plane of the slab. In order for the stove to look flat to the naked eye (although it really is not flat), considerable skill and skill are required to achieve the proper appearance when the user is working above the plane of the stove. Additional layers of suture sealant must be gradually leveled wider and wider from the seam so that the seam gives the impression of an aesthetically flat. If the user is not qualified enough, the appearance will be unsatisfactory.

[0007] It should be noted that the present description of the prior art was created by the inventors to help the reader and should not be construed either as a reference to the prototype, or as an indication that any of these tasks was considered in itself in the art. Although some of the principles described, in some respects and implementations, may alleviate the complexities associated with other systems, it should be noted that the scope of this protected improvement is determined by the appended claims, and not by the ability of the claimed invention to solve any specific tasks specified in the present description .

SUMMARY OF THE INVENTION

[0008] According to one aspect of the present invention, a drying type suture sealant composition is provided. The suture sealant composition contains, consists of or consists essentially of a binder selected from acrylic acid polymers, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds. The composition also contains many hollow balls. Preferably, said balls have an average isostatic crush strength of at least 100 psi (689 kPa), measured according to ASTM D3102-78.

[0009] According to another aspect of the present invention, there is provided a suture sealant composition consisting essentially of (a) a latex emulsion binder in an amount of from about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow balls having an average isostatic crushing strength of at least 100 psi (689 kPa), measured according to ASTM D3102-78, said balls being present in an amount of from about 5% to about 25% by weight of the wet composition; (c) a nonionic surfactant in an amount of from about 0.001% to about 5% by weight of the wet composition; and (d) a humectant in an amount of from about 0.001% to about 3% by weight of the wet composition; and, optionally, (e) an antifoam in an amount of from about 0.05% to about 5% by weight of the wet composition; (f) a rheological modifier in an amount of from about 0.1% to about 5% by weight of the wet composition; (g) a biocide in an amount of from about 0.1% to about 1.5% by weight of the wet composition; (h) a bulking agent such as calcium carbonate or limestone in an amount of from about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of from about 0.1% to about 5% by weight of the wet composition.

[0010] According to another aspect of the present invention, there is provided a wall structure comprising, consisting of or consisting essentially of two adjacent boards connected by a seam. To ensure a uniform aesthetically attractive appearance, a single layer of suture sealant is applied to the seam. The suture sealant composition contains a binder selected from acrylic acid polymers, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds. The composition also contains many hollow balls. Preferably, said balls have an average isostatic crush strength of at least about 100 psi (689 kPa), measured according to ASTM D3102-78. The wall structure further comprises a dimensionally stable, non-swellable flat tape for sealing the seams included in the seam.

[0011] According to another aspect of the present invention, there is provided a method of processing a wall plate structure consisting of two adjacent plates connected by a seam. The specified method includes, consists of or consists essentially of applying a tape for gluing joints and one coating layer of the composition of the joint sealant on the joint. The suture sealant composition contains a binder selected from acrylic acid polymers, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds. The composition also contains many hollow balls. Preferably, said balls have an average isostatic crush strength of at least about 100 psi (689 kPa), measured according to ASTM D3102-78. The specified method further includes drying the composition.

[0012] According to another aspect of the present invention, there is provided a reinforcing patch for protecting a seam between two adjacent plates having opposite front and rear surfaces, said front surfaces being located relative to one another, forming an angle between the front surfaces of the plates. The patch comprises, consists of, or consists essentially of a paper cladding containing a non-swellable synthetic paper cladding material and a substrate. For example, the cladding material may be laminated to a durable, corrosion-resistant material designed to provide excellent long-term reinforcement of the corner joint that exceeds the minimum performance specified in ASTM C1047-10a (standard specifications for components for gypsum wallboard and gypsum board base under plaster), from the point of view of resistance to cracking and chipping, with the formation of the angle vertex as a result, which remains a straight line normal movement and / or displacement of buildings and everyday wear and tear. In some embodiments, the substrate comprises a metal, such as galvanized steel and / or other substrate material, having the above required properties, including, for example, a multilayer composite structure, laminated paper, thermoplastic material, thermoset material, carbon fiber, polyester, polycarbonate , spun polyolefin, natural or synthetic fiber, woven material, and the like.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS (DRAWINGS)

[0013] FIG. 1 is a perspective view of a wall structure.

[0014] FIG. 2A-2B are alternative cross-sectional views obtained substantially along line 2-2 of FIG. 1, and in FIG. 2A shows a conventional bevel for comparison purposes, while FIG. 2B shows a more sloping bevel according to embodiments of the present invention.

[0015] FIG. 3A-3B are alternate cross-sectional views of a finished joint between two wall plates with beveled adjacent edges, with FIG. 3A shows a seam with a conventional wide distribution of suture sealant for comparison purposes, while in FIG. 3B shows a narrower distribution of suture sealant closer to the plane of the slab according to embodiments of the present invention.

[0016] FIG. 3C-3D are alternate cross-sectional views of a finished joint between two wall plates with square (i.e., non-beveled) adjacent edges, and in FIG. 3C shows a seam with a conventional wide distribution of suture sealant for comparison purposes, while in FIG. 3D shows a narrower distribution of suture sealant closer to the plane of the slab according to embodiments of the present invention.

[0017] In FIG. 4A and 4B are an exploded perspective view showing an armored patch superimposed on an angle formed by two wall plates, in FIG. 4A shows an external angle with an angle (x), while FIG. 4B shows an internal angle with an angle (y).

[0018] FIG. 5 shows two adjacent boards attached to a carcass structure, the V-shaped cutout allowing to see the presence of glue on the carcass elements according to the embodiments of the present invention.

[0019] In FIG. 6-7 shows the installation of wall structures, and in FIG. 7 shows the finished design of the room after painting, and FIG. Figure 8 shows the joints sealed with tape for sealing the joints before applying the joint sealant.

[0020] In FIG. 8 shows corner reinforcing pads according to embodiments of the present invention.

[0021] In FIG. 9 shows an angular reinforcing plate fixed in the inner corner with a self-adhesive material according to embodiments of the present invention.

[0022] FIG. 10-11 show the installation of a reinforcing patch in the corners using a roller according to embodiments of the present invention.

[0023] In FIG. 12 shows corner reinforcing pads according to embodiments of the present invention.

[0024] In FIG. 13 shows wall structures that allow one to see corner reinforcing pads mounted on internal and external corners, according to embodiments of the present invention.

[0025] In FIG. 14 shows a reinforcing patch for an inner corner with one layer of joint sealant according to embodiments of the present invention.

[0026] In FIG. 15 shows a sanded single-layer finish, both for joining in the machining direction (horizontally, as shown) and butt-joining (vertically, as shown), according to embodiments of the present invention.

[0027] FIG. 16 shows the installation of a wall structure with applied joint treatment.

[0028] In FIG. 17 shows a machined wall structure with a V-neck that allows you to see the glue and one coating layer with a joint sealant on the frame element, illustrating the narrow distribution of the sealant according to embodiments of the present invention.

[0029] FIG. 18, for comparison purposes, a conventional joint processing system for a joint seal tape included in a joint sealant is shown with two additional layers of joint sealant applied over the tape, which requires wide distribution of the joint sealant.

[0030] In FIG. 19-21 show a bending strength test process for sample 2A of Example 2 for comparison purposes.

[0031] In FIG. 22-24 show a bending strength test process for sample 2B of Example 2 for comparison purposes.

[0032] FIG. 25-27 show a bending strength test process for sample 2C of Example 2 according to embodiments of the present invention.

[0033] FIG. 28-29 show the bending strength for sample 2C of Example 2 according to embodiments of the present invention.

[0034] FIG. 30 is a box diagram showing pressure displacement when the first crack measured in inches (Y axis) and various joint sealants according to embodiments of the present invention and comparative examples (X axis) were observed.

[0035] FIG. 31 is a box diagram showing the load (in pounds) when the first crack was measured, measured in pounds (f) (Y axis), and various joint sealants according to embodiments of the present invention and comparative examples (X axis).

[0036] FIG. 32 is a box diagram showing shear displacement when the first crack measured in inches (Y axis) and various joint sealants according to embodiments of the present invention and comparative examples (X axis) were observed.

[0037] FIG. 33 is a box diagram showing peak shear displacement when the first crack measured in inches (Y axis) and various joint sealants according to embodiments of the present invention and comparative examples (X axis) were observed.

[0038] FIG. 34 is a box diagram showing the ratio of shear displacement (i.e., the ratio of peak displacement due to failure of the joint system to displacement at the time of the first crack) (Y axis), and various joint sealants according to embodiments of the present invention and comparative examples (X axis )

[0039] FIG. 35A shows a modified ASTM E72 frame construction of a size of 8 'x 8' (about 2.4 mx about 2.4 m) with a frame made of 2 ”x 4” wood blocks (about 5 cm x about 10 cm). Wooden bars are not shown.

[0040] In FIG. 35B shows a modified ASTM E72 frame design with FIG. 35A, equipped with 2 ”x 4” wooden blocks spaced 16 inches apart (approximately 0.4 meters).

[0041] FIG. 35C shows a modified ASTM E72 frame design with FIG. 35B, the bottom of which is rigidly attached to the structure, and a force is applied to the upper left corner using a hydraulic piston programmed to move along a sinusoidal path with a variable amplitude.

[0042] In FIG. 36A - 36C show a drying profile of suture sealants according to the present invention, compared with conventional suture sealants, for a thick coating layer, i.e. about 3/16 inch (about 0.5 cm), which shows the percentage of evaporated water (Y axis), depending on the increasing drying time represented by (X axis). In FIG. 36A shows mild drying profiles, for example 75 ° F (24 ° C) and 50% relative humidity. In FIG. 36B shows drying profiles in hot and dry conditions, for example 95 ° F (35 ° C) and 10% relative humidity. In FIG. 36C shows drying profiles in cold humid conditions, for example, 40 ° F (4 ° C) and 80% relative humidity.

[0043] FIG. 37A-37C show the drying profile of suture sealants according to the present invention compared to conventional suture sealants for a thin coating layer, i.e. about 1/16 inch (about 0.2 cm), which shows the percentage of evaporated water (Y axis), depending on the increasing drying time represented by (X axis). In FIG. 37A shows mild drying profiles, for example, 75 ° F (24 ° C) and 50% relative humidity. In FIG. 37B shows drying profiles in hot and dry conditions, for example 95 ° F (35 ° C) and 10% relative humidity. In FIG. 37C shows drying profiles in cold wet conditions, for example, 40 ° F (4 ° C) and 80% relative humidity.

DETAILED DESCRIPTION OF THE INVENTION

[0044] According to various embodiments, the present invention relates to suture sealant compositions, tile finish systems, wall structures, wall treatment methods and products related to any of the above applications, including a reinforcing patch, for example, to protect corners at the joints of plates, fasteners and tape for gluing seams. Other aspects of the present invention advantageously provide significant efficacy in the decoration of wall structures including a cladding, such as gypsum dry plaster, a board having a protective coating (for example, fiberglass cladding), and similar claddings. For example, the present invention provides the ability to finish walls with a significantly smaller number of steps required for any given level of finish, for example, level 4 finish according to the document of the association of manufacturers of gypsum GA-214 and / or ASTM C840 ("level 4"). As a result, wall decoration can be done faster with less downtime. In addition, wall decoration according to aspects of the present invention requires lesser user skill in installing the cladding.

[0045] One aspect of the present invention is based, at least in part, on the unexpected and unexpected opening of the suture sealant composition having low shrinkage. As a result, suture sealant can advantageously be applied in a smaller number of layers than conventional suture sealants. In some embodiments, only one layer of suture sealant is applied over fasteners, tape for seams, or reinforcing pads. However, if necessary, more than one coat (for example, two or three coats) can be applied, depending on the desired level of finish. For example, a drawback of conventional systems is significant shrinkage, such as, for example, shrinkage in excess of 15%, for example, about 18% or more. Embodiments of the present invention provide significantly less shrinkage. Embodiments of the joint sealant also have the required flexibility properties and can be easily sanded and, preferably, without cracking.

[0046] Since the suture sealant composition can be applied in a smaller number of layers, advantageously, the user can work with the suture sealant closer to the plane of the plate. Typically, in multi-layer (e.g. 3 layers or more) systems, the user should widely distribute the joint sealant at a great distance from the joint to provide a visual illusion of a flat surface. Significant user qualifications are required to obtain such an appearance if the thickness of the joint sealant rises significantly above the plane of the plates and the joints of the plates. Due to the use of a single-layer suture sealant according to embodiments of the present invention, the user will not be forced to distribute the suture sealant so widely, and less user skill will be required to obtain a flat appearance. In some embodiments, the slab is specifically designed with a smaller bevel than a conventional slab, or no bevel at all (i.e., a non-chamfered edge) in the direction of processing of the edges, as described herein.

[0047] According to other aspects of the present invention, there is provided a special non-swellable material that can be used in the tape for sealing joints, as well as the front layer of a reinforcing lining of composite material used to mask and protect the corners of walls in which two plates converge at an angle ( for example, in the “inner” corner or “outer” corner, as is understood in the art). The patch may also include a substrate (for example, including metal or other material) to provide rigidity and support.

[0048] Adhesive can be used in various aspects of the present invention. In some embodiments, the adhesive is a water-based quick-drying adhesive, such as a water-based wall adhesive (e.g., such as sold by Roman Adhesives), an aqueous binder (e.g., such as adhesives sold by the United States Gypsum Company), or an adhesive based on an aqueous latex emulsion (for example, such as an adhesive sold by OSI). For example, such glue can be applied to frame elements to minimize the number of fasteners used to install the slab. The glue can also be used to facilitate the application of tape for sealing joints and reinforcing pads according to the options for implementing the present invention.

[0049] According to embodiments of the present invention, fasteners corresponding to one layer of joint sealant can be used. For example, fasteners may include a concave surface head to create a deepening effect, although other types of fasteners are possible, including staples or other dry stucco screws. One or more of these various aspects can be combined in a tile system according to embodiments of the present invention.

[0050] The following are references to figures depicting advantageous illustrative embodiments of the present invention. In FIG. 1 shows a wall structure 100 including three boards 110, 112 and 114, attached to frame members 116 by means of fasteners 118. Any suitable cladding may be used as the boards. For example, a gypsum board typically contains an inner layer containing an interpenetrating matrix of crystalline gypsum with the desired additives, such as polyphosphate, starch, dispersing agent, accelerator, retarder, etc., between two covering sheets in a layered structure. The inner layer optionally may include a topcoat located on the surface of the inner layer facing one or both covering sheets. The present invention is not limited to cladding techniques, and the slab can be made by any suitable method known in the art.

[0051] The frame members 116 are desirably provided with glue 120 to facilitate adhesion to boards 110, 112, and 114 and to allow fewer fasteners 118 to be used than would be the case in conventional systems. Since fasteners must be closed with joint sealant, reducing the number of fasteners is beneficial in terms of efficiency, ease and quality of installation.

[0052] The edges of the slabs are usually defined as being in the processing direction or in the transverse direction, based on the location of the slab on the production line. Edges in the processing direction are usually longer edges and are usually wrapped with a covering sheet (e.g., made of paper) during plate production, in which a suspension of binder material is applied to a moving covering sheet (e.g., on a conveyor), producing an initially long, continuous prefabricated tape a plate, which is then cut in the transverse direction to the required dimensions, known in the art, for example, 4 'X 8' (1.2 x 2.4 m); 4 'X 10' (1.2 x 3.0 m); 4 'X 12' (1.2 x 3.7 m); etc., although various lengths and widths are possible, including a slab 36 inches wide (91 cm) or 54 inches wide (137 cm wide). For example, plate 110 has edges in the processing direction 122 and 124 and edges in the transverse direction 126 and 128. Similarly, plate 112 has edges in the processing direction 130 and 132 and edges in the transverse direction 134 and 136, while plate 114 has edges in the processing direction 138 and 140 and the edges in the transverse direction 142 and 144. As discussed in FIG. 2A and 2B below, the edges in the machining direction are usually beveled. The cutting edges in the transverse direction are usually not beveled.

[0053] The two plates can converge in different configurations, forming a seam, also called a joint. Since the edges in the processing direction are beveled, while the edges in the transverse direction are not beveled, the nature of the joints will change depending on which edges of the plates are joined. When the edge of the plate in the processing direction is joined with the edge of another plate in the processing direction, a seam is formed in the processing direction in which two bevels form a recess. If the edge in the transverse direction of one plate meets the edge in the transverse direction of another plate, a butt weld is formed, without recesses. As shown in FIG. 1, plates 110 and 112 are connected to form a seam in the processing direction 146, and plates 112 and 114 are connected to form a butt seam 148.

[0054] FIG. Are shown to illustrate the beveled edges of the plate in the processing direction. 2A and 2B, which are cross-sectional views illustrating options for the bevel depth of the plate 110. The inner portion 210 of the plate has an upper surface 212 and a lower surface 214. Typically, the upper covering sheet of the upper face 212 is wrapped around the edge in the processing direction 124 and is joined to the lower the sheet of paper facing the bottom surface 214. It will be appreciated that the laminate structure of the plate 110 with the inner layer 210 between the two cover sheets is usually formed with the upper side down, so that the upper surface 212 is located below. If desired, the stove can be turned over during production before being placed in the oven to dry the excess water. The inner layer 210 may optionally contain coating layers known in the art, for example, on the upper surface 212 and / or lower surface 214.

[0055] In FIG. 2A shows a conventional bevel 216 with significant depth (D), whereby a recess 218 is formed. Since a conventional joint sealant is susceptible to significant shrinkage, the depth (D) is large enough to correspond to the receipt of a large amount of joint sealant in the recess 218 to include tapes for seams to compensate for shrinkage during drying. A bevel with a considerable depth (D) is additionally made with the possibility of assisting the user by lowering the height above the plane of the plate, on which they work with additional layers of joint sealant in conventional systems. For example, conventional bevels can give a recess depth of about 0.08 inches (0.2 cm) at the deepest point. Even with such a normal bevel depth (D), the user still has to work with the joint sealant at a considerable height above the plate plane, which is undesirable.

[0056] FIG. 2B shows an alternative bevel according to embodiments of the present invention. The inner layer of the plate 220 has an upper surface 222 and a lower surface 224. Typically, the upper covering sheet that is used to trim the upper face 222 is wrapped around the edge 124 in the machining direction and connected to the lower covering sheet that is used to finish the lower surface 224. The inner layer 220 may optionally contain coating layers known in the art, for example, on the upper surface 222 and / or lower surface 224. In the manufacture of the plate, you can first form the top side down, and then if desired and flip as described above.

[0057] As can be seen in FIG. 2B, bevel 226 has a depth (D) significantly less than usual, as shown in FIG. 2A. Such bevel 226 forms a recess 228 that is smaller than usual and particularly suitable for a low shrink joint sealant according to embodiments of the present invention. In some embodiments, they do not provide any bevel even in the processing direction, so that the plate has square edges (i.e., D = zero). So, since there may not be a bevel in various embodiments, bevel 226 can define a recess depth at the deepest point from 0 inches to about 0.05 inches (0.13 cm), for example, from about 0 inches to about 0.04 inches (0.10 cm), from 0 inches to about 0.03 inches (0.08 cm), from 0 inches to about 0.02 inches (0.05 cm), from 0 to about 0.015 inches (0.038 cm), from 0.005 inches (0.013 cm) to about 0.05 inches, from 0.005 inches to about 0.04 inches, from 0.005 inches to about 0.03 inches, from 0.005 inches to about 0.02 inches, from 0.005 inches to about 0.015 inches, from 0.01 inches to about 0.05 d yma, 0.01 inch (0.025 cm) to about 0.04 inches, 0.01 inches to about 0.03 inches, 0.01 inches to about 0.02 inches, etc.

[0058] FIG. 3A-3D are cross-sectional views illustrating various arrangements for finishing level 4 joints between two wall plates. In particular, FIG. 3A and 3B illustrate the connection between two beveled plates (i.e., plates joined in the processing direction), FIG. 3A illustrates a conventional system with multiple layers of joint sealant for comparison purposes, and FIG. 3B illustrates one layer of suture sealant according to embodiments of the present invention. FIG. 3C and 3D illustrate a joint in which two square edges are joined without bevels (i.e., a butt joint or a joint in the machining direction without a bevel). In this regard, FIG. 3C illustrates a conventional multilayer system for comparison purposes, while FIG. 3D illustrates the application of a single layer of suture sealant according to embodiments of the present invention. Although the internal parts of the boards are shown, it is understood that the cover sheets can be applied as described above.

[0059] FIG. 3A, the slab structure 300 includes a first slab 302 including an inner portion 304 and a chamfered edge 306. The second slab 308 includes a chimney 310 and a chamfered edge 312. The chamfered edges 306 and 312 converge to form a chamfered joint 314. A tape 316 is applied to the joint 314. for gluing seams. In conventional systems, a suture sealant layer 318 is required to turn on the tape 316 above the joint 314. Conventional feeding tools can be used to jointly feed the tape 316 and the suture sealant layer 318. After drying the suture sealant layer 318, a second layer of suture sealant 320 is applied over the tape 316. Then, after the second layer 320 has dried, a third layer of suture sealant 322 is applied over the second layer 320. In conventional systems, three layers of suture sealant 318, 320 and 322 are required to compensate for significant shrinkage resulting from chemical their processes in a conventional suture sealant.

[0060] In FIG. 3B shows a single layer system according to exemplary embodiments of the present invention. The slab structure 324 includes a first slab 326 including an inner portion 328 and a chamfered edge 330. The second slab 332 includes an inner part 334 and a chamfered edge 336. It will be appreciated that both chamfered edges 330 and 336 have less slope than the conventional chamfered edges 306 and 312 shown in FIG. 3A, as described in relation to FIG. 2B above. The tapered edges 306 and 312 converge to form a tapered connection 338. The tape 340 can be applied over the connection 338 using glue 342. The glue 342 can be positioned in any suitable way with respect to the tape 340, but in some embodiments, the adhesive is on the bottom surface of the tape 340 and optionally protected by an adhesive backing. The adhesive may be any suitable adhesive, for example, applied by pressure (such as, for example, using a hand, blade, roller or other device). In contrast to the conventional design shown in FIG. 3A, only one layer of suture sealant 344 is required, as shown in FIG. 3B.

[0061] FIG. 3C-3D illustrate alternative embodiments for joining with square edges (i.e., without beveling) that can be used for butt joining or for joining in the machining direction with square edges. In FIG. 3C, the slab structure 346 includes a first slab 348 including an inner portion 350 and a straight edge 352. The second slab 354 includes an inner portion 356 and a straight edge 358. The straight edges 352 and 358 converge to form a 360 joint with square edges. Tape 362 is applied over joint 360. In conventional systems, a layer of suture sealant 364 is required to incorporate tape 362 over joint 360. As indicated above, conventional feeding tools can be used to jointly feed tape 362 and a layer of suture sealant 364. After the suture sealant layer 364 has dried over tapes 362 apply a second layer of suture sealant 366. Then, after the second layer 366 has been poured, a third layer of suture sealant 368 is applied over the second layer 366. Three layers of suture sealant 318, 320 and 322 compensate for significant shrinkage that occurs in bychnom suture sealant.

[0062] In FIG. 3D shows a single layer system for joining square edges according to exemplary embodiments of the present invention. The plate structure 370 includes a first plate 372 including an inner portion 374 and a straight edge 376. A second plate 378 includes an inner portion 380 and a straight edge 382. The straight edges 376 and 382 converge to form a joint 384 with square edges. The tape 386 can be applied over the joint 384 using glue 388. The glue 388 can be positioned in any suitable manner with respect to the tape 386, but in some embodiments, the adhesive is on the lower surface of the tape 386 and is optionally protected by an adhesive backing. The adhesive may be any suitable adhesive, for example, applied by pressure. In contrast to the conventional design shown in FIG. 3C, only one layer of suture sealant 390 is required, as shown in FIG. 3D

[0063] In conventional systems, as shown in FIG. 3A and 3C, three layers of joint sealant (318, 320 and 322) and (364, 366 and 368) are required, whereby the user works with the joint sealant well above the plane (P) of the plate at a height (H), as shown. The height (H) is even more significant for options for the implementation of connections with square edges (which is usually for butt joints), as shown in FIG. 3C, since there is no bevel below the plane (P) of the plate containing a certain amount of sealant. For example, the height (H) of conventional systems may be at least about 0.1 inch (0.25 cm), for example at least about 0.125 inch (0.32 cm) or more. The user must have significant qualifications for working with sealant to create a flat look for the naked eye when working so high above the plane of the plate. Typically, the joint sealant is gradually distributed farther and farther from joint 314 or 360, respectively. Due to the considerable height (H), the sealant distribution has a substantial width (W), as shown, to create the appearance of a flat coated joint. For example, the width (W) in the conventional embodiments shown in FIG. 3A and 3C may be at least about 30 inches (76 cm), for example, about 36 inches (91 cm) or more for conventional systems.

[0064] Embodiments of the present invention shown in FIG. 3B and 3D, advantageously result in a lower height (H) and width (W) for the applied and distributed seam sealant compared to (H) and (W) for the respective conventional designs shown in FIG. 3A and 3C, respectively. Since the user does not need to work so high above the plane (P) of the plate, therefore, there is no need to distribute the sealant layer 344 and 390, respectively, as wide as in conventional systems in FIG. 3A and 3C. For example, the height (H) in some embodiments of the present invention may be less than 0.1 inches, and preferably the height (H) is less than 0.7 inches (1.78 cm), such as about 0.0625 inches (0.159 cm) or less or about 0.05 inches or less (for example, from 0.02 inches to about 0.1 inches, from 0.02 inches to about 0.07 inches (0.178 cm), from 0.02 inches to about 0, 0625 inches, from about 0.02 inches to about 0.05 inches, from about 0.05 inches to about 0.1 inches, from about 0.05 inches to about 0.07 inches, from about 0.05 inches to about 0.0625 inches, etc.). Similarly, the width (W) in the embodiments shown in FIG. 3B and 3D, for distributing the joint sealant 344 and 390, respectively, can be significantly less than the width (W) for the respective conventional systems (for example, shown in FIGS. 3A and 3C). For example, a smaller width (W) according to preferred embodiments of the present invention may be about 20 inches (51 cm) or less, such as about 18 inches (46 cm) or less, 15 inches (38 cm) or less, 12 inches (30 5 cm) or less (for example, from about 5 inches (12.7 cm) to about 20 inches, from about 5 inches to about 15 inches, from about 5 inches to about 12 inches, from about 5 inches to about 10 inches (25.4 cm), etc.).

[0065] FIG. 4A and 4B show illustrative embodiments of weld processing in which the boards converge at an angle, for example, forming a corner of a wall. An angular reinforcing plate can fix and reinforce corners, ensuring integrity between intersecting gypsum panels, and hide the corner seams between gypsum panels, being covered with sealant. For example, to illustrate the outer corner, in FIG. 4A shows a wall structure 400 including a first plate 410 with a face 412. The second plate 420 has a face 422. The plates 410 and 420 converge at an angle to form an angular seam 424 adjacent to the front edge 426 of the plate 410. Angle (x) defined the intersection of the front sides 412 and 422, is considered in the art as an outer corner. The outer corner may be any suitable angle, depending on the wall configuration and dimensions, as is clear in the art. Typically, the angle (x) is an angle larger than the expanded angle, but smaller than the full angle, as shown in FIG. 4A, i.e. an angle exceeding 180 °, although smaller angles are possible in the case of more specific angles. For example, in some embodiments, the angle (x) may be in the range of, for example, from about 180 ° to about 300 °, including angles of about 270 °, such as from about 230 ° to about 330 °, from about 250 ° to about 310 °, from about 260 ° to about 300 °, from about 260 ° to about 280 °, from about 265 ° to about 275 °, or from about 268 ° to about 272 °.

[0066] As can be seen in the image in expanded form in FIG. 4A, a reinforcing pad 428 is applied over the outer fillet 424 and the front edge 426 to close and protect the edge 426 and the seam 424. The pad 428 includes the front of the pad 430 with the reinforcing pad 432, the width of which does not exceed the width of the front of the pad 430 in some embodiments implementation. Adhesive 434 is used to apply the overlay 428 to the outer fillet 424 and the front edge 426. A suture sealant, including one layer of suture sealant according to embodiments of the present invention, is applied over the underlay to conceal the overlay and the seam. After application and drying, the sealant can be sanded and painted to ensure a uniform aesthetically pleasing appearance.

[0067] To illustrate the internal angle, in FIG. 4B shows a wall structure 450 including a first plate 452 with a face 454. The second plate 460 has a face 462. The plates 452 and 460 converge at an angle to form an angular seam 464. The angle (y) defined by the intersection of the front sides 454 and 462 is considered in the art as an internal angle. The internal angle may be any suitable angle, depending on the wall configuration and dimensions, as is clear in the art. Typically, the angle (y) is an angle less than 180 °, although larger angles are possible with more specific angles. For example, in some embodiments, the angle (y) may be in the range of, for example, from about 30 ° to about 180 °, or from about 45 ° to about 135 °, including angles of about 90 °, such as from about 60 ° to about 120 °, from about 70 ° to about 110 °, from about 80 ° to about 100 °, from about 85 ° to about 95 °, or from about 88 ° to about 92 °.

[0068] As can be seen in the image in expanded form in FIG. 4B, a reinforcing pad 466 is applied over the inner fillet weld 464 to close and protect the seam 464. The pad 466 includes a front portion of a pad 468 with a reinforcing substrate 470 whose width does not exceed the width of the front of the pad 468 in some embodiments. Glue 472 is used to apply the patch 466 to the seam 464. Suture sealant, including one layer of suture sealant according to embodiments of the present invention, is applied over the patch to conceal the patch and the seam. After application and drying, the sealant can be sanded and painted to ensure a uniform aesthetically pleasing appearance.

[0069] In some embodiments, the face of the patch 430 or 468 desirably includes non-swellable paper (natural or synthetic). Non-swelling paper is especially desirable in single-layer systems, since less sealant will be on top of the paper and mask any unwanted swelling that can lead to bloating or other unattractive effects. For example, in some embodiments, the front portion 430 or 468 has a dimensional stability of less than about 0.4% expansion in the processing direction (BUT) and less than about 2.5% expansion in the transverse direction (MON) (for example, less than about 0.3 % ND expansion and less than about 1.5% ND expansion, such as less than about 0.2% ND expansion and less than about 1% ND expansion) after 30 minutes immersion in water according to ASTM C474-05, section 12. It is understood that implementations meeting the test of ASTM C474-05 may also exceed the minimum e performance requirements specified in ASTM C475 / C475M Standard - 12 "Specifications for seam sealant and tape for sealing up joints for finishing gypsum board."

[0070] In some embodiments, the face portion 430 or 468 has a thickness of from about 0.01 inches (≈ 0.0254 cm) to about 0.125 inches (≈ 0.318 cm), such as from about 0.05 inches (≈ 0.127 cm) up to about 0.0625 inches (≈ 159 cm). It is clear that the tape for sealing joints can contain the same materials, characteristics and properties as the front part of the reinforcing lining.

[0071] The substrate 432 or 470 of the reinforcing plate 428 or 466 may contain any suitable material that provides strength to the composite material of the plate. The substrate material is suitable for reducing, controlling or eliminating cracking of the seam in the corners of the walls, if there are shifts of the frame of the new design and minor displacements of the walls. The substrate material also, together with the material of the front part, performs the function of forming a regular and straight angular line along the vertex at which the two walls converge or intersect, forming an angle. For example, the backing pad 432 or 470 may include a composite multilayer structure, multilayer paper (synthetic or natural), thermoplastic material, thermosetting material, natural or synthetic fiber, carbon fiber, polyester, polycarbonate, fiberglass, non-woven natural or synthetic materials, woven natural or synthetic materials, spun polyolefin, or metals, such as steel, for example, electrically galvanized and / or hot galvanized, treated with zinc phosphate and / or high coated with a chromate primer, and / or otherwise processed or coated metal, and the like. For example, in one typical embodiment, the substrate 432 or 470 is made of galvanized steel. Preferably, the substrate 432 or 470 has any suitable thickness, i.e. a thickness of at least about 0.010, for example, from about 0.012 inches (≈ 0.030 cm) to about 0.0625 inches (≈ 0.159 cm), such as from about 0.012 inches to about 0.030 inches (≈ 0.0762 cm). In some embodiments, a support material is used, such as galvanized steel, in which case the substrate typically gives Rockwell B hardness from about 45 to about 85, such as from about 55 to about 65, measured according to ASTM E18-03.

[0072] The manufacture of overlays is shown for embodiments with a non-swellable paper face and a galvanized steel backing. Pads are obtained by passing sheet steel (on a coil) through a series of gradually changing dies, with the material of the front part and the metal substrate being introduced immediately after the last set of dies. The front part and the substrate in some embodiments, the implementation can be glued to each other hot. Other techniques for the manufacture of reinforcing pads made of various materials will be clear to a person skilled in the art.

[0073] FIG. 5-18 are photographs depicting various illustrative embodiments of the present invention. In particular, in FIG. 5 shows a cutout of a slab to show panel glue applied to a frame. In FIG. 6 shows the design of the room after staining. As can be seen in FIG. 6, the finished wall structure according to the embodiments of the present invention can obtain a level 4 finish of dry plaster with one layer of joint sealant and without the need for many layers of joint sealant, as in conventional systems. In addition, in FIG. 7 shows a tape for gluing joints glued to the seams of gypsum panels before processing the gypsum panels with joint sealant.

[0074] With regard to the structures of the inner and outer corners, in FIG. Figure 8 shows the outer corner pads made of a non-swelling paper lining with a metal substrate. Moreover, in FIG. 9 shows a reinforcing pad for an inner corner, with a non-swelling paper lining on a metal substrate, manually glued into place. In FIG. 10-11 illustrate the installation of embodiments of a patch according to the present invention using a roller. In FIG. 12 shows details of an outer corner patch. In FIG. 13 shows the design of the room, on which all overlays for internal and external corners and flat tapes for sealing joints are installed. In FIG. 14 shows a flat tape for gluing seams on a corner patch in the upper left corner of the image. In the lower right corner of the image shows one layer of suture sealant, applied to provide level 4 finish dry plaster according to the options for implementing the present invention.

[0075] FIG. 15 shows a flat tape for sealing joints with one layer of suture sealant applied on the left side of the image. It can be seen that the butt joint (joint across the machining direction) without beveling was closed by applying one layer of suture sealant and then ground. On the right side of the image, a finished painted view is shown. In FIG. 16 shows the design of a room with established connection processing, while FIG. 17 shows a cutout of a finished wall to show panel adhesive applied to the frame using a tape for sealing joints and one layer of joint sealant. Further, in FIG. 18 shows a gypsum board with a conventional level 4 finish of dry plaster with a distribution width of only 12 inches, according to embodiments of the present invention.

[0076] In these and other embodiments, the suture sealant composition of the present invention includes (a) an astringent, (b) hollow balls (sometimes called bubbles) with an average isostatic crush strength of at least about 100 psi (689 kPa) (eg, at least about 250 psi (1724 kPa)) according to ASTM D 3102-78, and optionally other ingredients. Preferably, the suture sealant composition has low shrinkage. For example, in some embodiments, the suture sealant composition has a shrink of about 10% or less in volume, for example about 7% or less, such as about 5% or less, about 2% or less, about 1% or less, about 0 , 1% or less, or near zero (no shrinkage), according to ASTM C474-05, section 6.

[0077] The suture sealant may have any suitable density, but is preferably a particularly lightweight composition having a density of about 10 f / gal. (≈ 1200 kg / m ³ ) or less, such as about 8 psig. or less. For example, in some embodiments, the joint sealant has a density of about 2 psig. (≈ 240 kg / m ³ ) up to about 8 f / gal. (≈ 960 kg / m ³ ) (preferably from about 2 f / gal. To about 6 f / gal. (≈ 720 kg / m ³ ), more preferably from about 3 f / gal. (≈ 360 kg / m ³ ) to about 4 lb / gal. (≈ 480 kg / m ^3)).

[0078] In general, the composition is a drying type suture sealant, the sealant hardening due to the evaporation of water. Thus, in some embodiments, the suture sealant composition is substantially free of settable materials such as calcined gypsum, cement, or other hydraulic settable materials. In addition, in some embodiments, the suture sealant composition may desirably substantially contain no raw materials such as bulk filler, clays, starch, or mica; including examples such as calcium carbonate, expanded perlite, calcium magnesium carbonate, limestone, calcium sulfate dihydrate, gelling clay such as attapulgite clay, delaminated clay such as kaolin clay, talc and diatomaceous earth. In addition, the suture sealant composition may desirably substantially not contain any combination of the above raw materials.

[0079] As used herein, “substantially free” of such settable minerals, bulk filler, clays, starch, mica, or a combination of these materials means that the suture sealant composition contains (i) 0% by weight. by weight of the composition, or does not contain such settable minerals, bulk filler, clays, starch, mica, or a combination of these materials, or (ii) ineffective, or (iii) an insignificant amount of such settable minerals, volumetric filler, clays, starch, mica, or a combination specified materials. An example of an ineffective amount is an amount less than a threshold amount to achieve the intended purpose of using such setting minerals, bulk filler, clays, starch, mica, or a combination of these materials, as one of ordinary skill in the art will understand. A minor amount may be, for example, less than about 5% by weight, such as less than about 2% by weight, less than about 1% by weight, less than about 0.5% by weight, less than about 0.2% by weight, less than about 0.1% of the mass. or less than about 0.01 wt. -%, as is understood by the average person skilled in the art. However, if necessary in alternative embodiments, these ingredients may be included in the suture sealant composition.

[0080] In alternative embodiments, a bulky filler (eg, calcium carbonate or limestone) or delaminated clay such as kaolin clay may be present. These raw materials can be introduced, in some embodiments, to give the suture sealant the subjective consistency desired by the end user during the application process. These raw materials, in the present description, do not otherwise change the physical properties of the suture sealant. In such embodiments, up to 40% of the mass may be included. bulk filler such as calcium carbonate or limestone. If present, in some embodiments, the bulky filler may be present, for example, in an amount of up to about 35% by weight, up to about 30% by weight, up to about 25% by weight, up to about 20% by weight, up to about 15% by weight ., up to about 10% of the mass., up to about 5% of the mass. or up to about 1% of the mass. by weight of the wet composition. Each of these boundary values may have a lower limit, for example, in the range from 1% wt., 5% wt., 10% wt., 15% wt., 20% wt., 25% wt., 30% wt. or 35% of the mass., suitable quantitatively.

[0081] For example, in some embodiments, the bulky filler may be present in an amount of from about 1% of the mass. up to about 40% of the mass., for example, from about 1% of the mass. up to about 30% of the mass., from about 1% of the mass. up to about 25% of the mass., from about 1% of the mass. up to about 20% of the mass., from about 1% of the mass. up to about 15% of the mass., from about 1% of the mass. up to about 10% of the mass., from about 5% of the mass. up to about 30% of the mass., from about 5% of the mass. up to about 25% of the mass., from about 5% of the mass. up to about 20% of the mass., from about 5% of the mass. up to about 15% of the mass., from about 5% of the mass. up to about 10% of the mass., from about 10% of the mass. up to about 30% of the mass., from about 10% of the mass. up to about 25% of the mass., from about 10% of the mass. up to about 20% of the mass., from about 15% of the mass. up to about 30% of the mass., from about 15% of the mass. up to about 25% of the mass. or from about 20% of the mass. up to about 30% of the mass.

[0082] If present, a delaminated clay, such as kaolin clay, may be present, in some embodiments, for example, in an amount of up to about 5% by weight, up to about 4.5% by weight, up to about 4% by weight, up to about 3.5% wt., up to about 3% wt., up to about 2.5% wt., up to about 2% wt., up to about 1.5% wt., up to about 1% wt., up to about 0 5% of the mass. or up to about 0.1% of the mass. by weight of the wet composition. Each of these boundary values may have a lower limit, for example, in the range from 0.1% wt., 0.5% wt., 1% wt., 1.5% wt., 2% wt., 2.5% mass., 3% of the mass., 3.5% of the mass., 4% of the mass. or 4.5% of the mass., suitable quantitatively.

[0083] For example, in various embodiments, delaminated clay, such as kaolin clay, may be present in an amount of from about 0.1% of the mass. up to about 5% of the mass., for example, from about 0.1% of the mass. up to about 4% of the mass., from about 0.1% of the mass. up to about 3% of the mass., from about 0.1% of the mass. up to about 2% of the mass., from about 0.1% of the mass. up to about 1% of the mass., from about 0.1% of the mass. up to about 0.5% of the mass., from about 0.5% of the mass. up to about 5% of the mass., from about 0.5% of the mass. up to about 4% of the mass., from about 0.5% of the mass. up to about 3% of the mass., from about 0.5% of the mass. up to about 2% of the mass., from about 0.5% of the mass. up to about 1% of the mass., from about 1% of the mass. up to about 5% of the mass., from about 1% of the mass. up to about 4% of the mass., from about 1% of the mass. up to about 3% of the mass., from about 1% of the mass. up to about 2% of the mass., from about 2% of the mass. up to about 5% of the mass., from about 2% of the mass. up to about 4% of the mass., from about 2% of the mass. up to about 3% of the mass., from about 3% of the mass. up to about 5% of the mass., from about 3% of the mass. up to about 4% of the mass. or from about 4% of the mass. up to about 5% of the mass.

[0084] Any suitable binder can be used to produce the desired suture sealant according to aspects of the present invention. Selected binders hold together the particles of the composition and form a film. In some embodiments, the binder is selected from polymers of acrylic acid, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides, and combinations of these compounds. In some embodiments, the binder has a glass transition temperature (Tg) of about 32 ° F (≈ 0 ° C) to about 70 ° F (≈ 21 ° C), for example, from about 32 ° F to about 66 ° F (≈ 18 ° C), such as from about 40 ° F (≈ 5 ° C) to about 60 ° F (≈ 15 ° C), for example, about 55 ° F (≈13 ° C). In some embodiments, the binder has a minimum film-forming temperature (MTP) of from about 32 ° F to about 90 ° F (≈ 32 ° C), for example, from about 32 ° F to about 86 ° F (≈ 30 ° C), such as from about 40 ° F (≈ 5 ° C) to about 60 ° F (≈ 15 ° C), for example, about 52 ° F (≈11 ° C).

[0085] In some embodiments, the binder can generally be any film-forming resin (or a combination of resins) capable of forming a solid film and holding solid materials on the surface onto which the suture sealant composition is applied. For example, the binder may be, in some embodiments, an acrylic acid polymer and / or an acrylic acid copolymer. The binder is in the form of an aqueous emulsion, in some embodiments, as a suitable latex emulsion, including, without limitation, acrylic polymers, such as, for example, vinyl-acrylic polymers and styrene-acrylic polymers. In some embodiments, suitable binders include acrylic latex, vinyl acrylic, vinyl acetate, polyurethane polymers and / or combinations of these materials.

[0086] Suitable latex emulsions include polyacrylate ester polymers sold under the trade names RHOPLEX® (Rohm & Haas), acrylic polymers, vinyl acrylic polymers, for example vinyl acetate-butyl acrylate copolymers, styrene acrylic polymers, and U NEOCAR ™ (The Dow Chemical Company, MI) such as UCAR ™ 367; emulsion polymer products sold under the trade name VINREZ® (Halltech, Inc., Ontario); vinyl acrylic polymers sold under the trade name Plioway® (Eliokem, Ohio); acrylic, vinyl acrylic and styrene acrylic latex polymers sold under the trade name AQUAMAC ™ (Resolution Specialty Materials, LLC, Illinois); and vinyl acrylic resin sold under the trade name VINREZ® 663 V15 (Halltech, Inc., Ontario), which has a glass transition temperature of about 18 ° C. Another binder based on a vinyl acrylic copolymer is sold under product trade name No. HP-31-496 (Halltech, Inc., Ontario) and has a glass transition temperature of about 0 ° C.

[0087] Suitable functionalized acrylic polymers, alkyds, polyurethanes, polyesters and epoxides can be obtained from a number of commercial sources. Suitable acrylic polymers are marketed under the trade name ACRYLOID ™ (Rohm & Haas, Co., PA); suitable epoxy resins are sold under the trade name EPON ™ (Resolution Specialty Materials, LLC, Illinois); suitable polyester resins are sold under the trade name CYPLEX® (Cytec Industries, NJ); and suitable vinyl resins are sold under the trade name UCAR ™ (The Dow Chemical Company, Michigan).

[0088] The binder may be included in the suture sealant composition in any suitable amount. For example, a binder can be included in an amount of from about 5% of the mass. up to about 100% of the mass. (by weight of dry matter) wet composition, such as from about 20% of the mass. up to about 80% of the mass., from about 30% of the mass. up to about 70% of the mass., from about 40% of the mass. up to about 60% of the mass., etc.

[0089] Hollow balls contain insulated air surrounded by a solid barrier. Since air is contained in a hard shell, air bubbles do not merge, so that air can be evenly distributed throughout the sealant and maintain a substantially uniform density. Hollow balls contribute to a lower density, but preferably have good strength properties, so that the hollow balls give resistance to crushing, due to which the dry suture sealant, after application, does not essentially crumble, in some embodiments, in contrast to a conventional suture sealant that crumbles and fragile.

[0090] Balls, in some embodiments, provide an ultralight suture sealant that results in the desired properties and creates less load for the user when lifting the sealant in buckets or the like. during the working day. The balls may have any suitable density, such as a density of from about 0.0015 psi to about 0.04 psi, for example, from about 0.0018 psi (≈ 0.05 g / cm ³ ) to about 0.036 psi (≈ 1 g / cm ³ ), such as from about 0.0036 psi (≈ 0.1 g / cm ³ ) to about 0.0253 psi . inch (≈ 0.7 g / cm ³ ). With regard to strength, for example, balls can have an average isostatic crush strength of at least about 50 psi (≈ 340 kPa) when measured according to ASTM D 3102-78, such as an isostatic crush strength of at least about 100 psi (≈ 690 kPa ) For example, isostatic crush strengths can range from about 50 psi to about 50,000 psi (≈ 344,740 kPa), from about 50 psi to about 25,000 psi (≈172,000 kPa), from about 50 psi to about 10,000 psi, from about 50 psi up to about 5000 psi (≈ 34000 kPa), from about 50 psi to about 1000 psi, from about 50 psi to about 500 psi (≈ 3450 kPa), from about 100 psi to about 50,000 psi, from about 100 psi to about 25000 psi , from about 100 psi to about 10,000 psi, from about 100 psi to about 5,000 psi, from about 100 psi to about 1000 psi, from about 100 psi to about 500 psi, from about 250 psi (≈ 17 20 kPa) to about 50,000 psi, from about 250 psi to about 25,000 psi, from about 250 psi to about 10,000 psi, from about 250 psi to about 5,000 psi, from about 250 psi to about 1000 psi, from about 250 psi to about 500 psi, from about 500 psi to about 50,000 psi, from about 500 psi to about 25,000 psi, from about 500 psi to about 10,000 psi, from about 500 psi to about 5,000 psi, from about 500 psi to about 1000 psi, from about 1000 psi to about 50,000 psi, from about 1000 psi to about 25,000 psi, from about 1000 psi to about 10,000 psi, from about 1000 psi to about 5,000 psi, from about 2,500 psi (≈ 17,200 kPa) to about 50,000 psi, from about 2500 psi to about 25000 psi, from about 2500 psi to about 10000 psi, from about 2500 psi to about 5000 psi, etc.

[0091] Examples of bead types according to embodiments of the present invention include calcareous borosilicate, polystyrene, ceramic material, recycled glass, foamed glass and light polyolefin granules, and / or any other chemical form of plastic. For example, in some embodiments, suture bead balls include, but are not limited to, soda lime borosilicate glass bubbles (e.g., sold under the trade name Scotchlite ™ (3M)), multi-walled hollow glass microspheres (e.g., sold under the trade name Omega- Bubbles ™ (Omega Minerals)), expandable polymer microspheres (for example, sold under the trade name DUALITE® (Henkel)), polyolefin microspheres and polystyrene microspheres (for example, sold under the trade name Spex • Lite® (Schabel Polymer Technology, LLC)), foam glass balls (for example, sold under the trade name Poraver® North America), and combinations of these materials. In illustrative embodiments, suitable beads may include Scotchlite ™ (3M) K1 and / or K15.

[0092] The balls may have any suitable diameter and may be provided in any suitable concentration. It is understood that the term balls is known in the art and does not imply a correct geometric sphere, since the balls may have an irregular shape. Thus, the diameter in the present description refers to the diameter of the smallest geometric sphere that would contain a real ball. In some embodiments, the spheres may have a diameter of from about 10 microns to about 100 microns, such as from about 40 microns to about 80 microns, or from about 50 microns to about 70 microns. As for the amount, in some embodiments, the pellets are present in an amount of from about 2% to about 50% by weight of the wet composition, such as, for example, from about 5% to about 35%, from about 7% to about 25%, or from about 10% to about 20%.

[0093] In some embodiments, the suture sealant composition optionally also includes a surfactant. It is desirable that the surfactant can help stabilize the binder so that flocculation of the binder is not observed. It is also desirable that the surfactant can provide a wetting or dispersing effect. In this regard, when dry raw materials enter water, dry materials can compete for water and form unwanted agglomerates. Thus, in some embodiments, a surfactant is included to increase ease of mixing when dry materials are included in the liquid, and to further facilitate pumping of the joint sealant from filling stations and buckets during production. The surfactant also provides advantages during application, when applying suture sealant, for example, using distribution tools known in the art.

[0094] For example, in some embodiments, the surfactant may be a non-ionic surfactant with a hydrophilic lipophilic balance (HLB) from about 3 to about 20, such as from about 4 to about 15, or from about 5 to about 10. It is understood that surfactants with HLB values below 9 are generally considered lipophilic, surfactants with HLB values of 11 to 20 are generally considered hydrophilic, and surfactants with HLB values of 9 to 11 in overall review they attack as transient. Suitable nonionic surfactants having an HLB below about 9 include, without limitation, octyl phenol ethoxylates and nonyl phenol ethoxylates, including non-ionic surfactants with an HLB below about 9, sold under the trade names TRITON ™ and TERGITOL ™ (The Dow Chemical Company, Michigan ) Suitable nonionic surfactants having an HLB above about 11 include octyl phenol ethoxylates and nonyl phenol ethoxylates containing more ethylene oxide units than non-ionic surfactants with an HLB below 9. Suitable non-ionic surfactants having an HLB above about 11 are also sold under trade name TRITON ™ (The Dow Chemical Company, Michigan). Other surfactants can also be used provided that the HLB value for the (mixture) of surfactant (s) is as described above for suture sealant compositions and combinations thereof. If present, the nonionic surfactant may be present in any suitable amount, such as from about 0.001% to about 15% by weight of the wet composition, such as from about 0.001% to about 10%, from about 0.001% to about 5%, or from about 0.01% to about 0.5%.

[0095] One or more defoamers, such as, for example, petroleum distillate or similar substances known in the art, are optionally included in the suture sealant composition in some embodiments. If present, the antifoam may be present in an amount of from about 0.01% to about 15% by weight of the wet composition, such as from about 0.05% to about 5%, or from about 0.3% to about 1%.

[0096] In some embodiments, a humidifier is optionally included. For example, humidifiers can be used to keep the joint sealant wet by promoting moisture retention, and they can also facilitate the use of mechanical dispensing tools. In particular, in some embodiments, one or more humectants are included in the water-based suture sealant composition to slow drying of the suture sealant composition and provide a more proper finish. Humidifiers can also advantageously provide resistance to freezing and thawing and / or stability of the joint sealant composition. Any suitable humectants may be included, such as, for example, sorbitol derivatives, polyhydric alcohols, including, but not limited to, glycols such as ethylene glycol, diethylene glycol (DEG), triethylene glycol, propylene glycol, dipropylene glycol and / or tripropylene glycol, or any combination of these compounds. If present, humectants may be included in an amount of from about 0.001% to about 15% by weight of the wet composition, such as from about 0.001% to about 10%, from about 0.01% to about 5%, or from about 0.001% to about 3 %

[0097] Optionally, in some embodiments, the suture sealant composition comprises a rheology modifier. If available, the rheological modifier generally improves certain rheological properties, such as fluidity, viscosity, application properties, and other performance characteristics of suture sealants. For example, in some embodiments, a rheology modifier is often introduced to provide coating compositions with desired viscosity values as described herein, for example, using CW Brabender visco-corder equipment to measure the viscosity of a joint sealant composition.

[0098] Suitable rheology modifiers for optional use in the composition of the sealant suture include, without limitation, cellulose, and associative thickeners, including, without limitation, the hydrophobically modified ethoxylated urethanes (HEUR), hydrophobically modified alkali swellable emulsions (HASE) and terpolymers of styrene- maleic anhydride (SMAT), and / or combinations of these compounds. Examples of cellulosic rheological modifiers include, but are not limited to, cellulose ethers such as hydroxyethyl cellulose (HEC), ethyl hydroxyethyl cellulose (EHEC), methyl hydroxyethyl cellulose (MHEC), carboxymethyl cellulose (CMC), other hydroxypropyl methyl cellulose and other cellulose ethers and ( from about 1,000 to 5,000,000 Daltons, for example, alkyl ethers of hydroxypropyl cellulose, hydroxypropyl methyl cellulose, as well as xanthan gums, sodium alginates and other salts of alginic acids, carrageenans, gum arabic (mixed salts of arabic acid), karaya gum (acetylated polysaccharide), tragacanth gum (a complex mixture of acid polysaccharides) ghatti gum (calcium and magnesium salt of a complex polysaccharide), guar gum and galactan (galactan) locust bean gum (branched galactomannan), tamarind gum, plantain seed gum, quince gum, larch gum, pectin and its derivatives, dextrans and hydroxypropyl cellulose, or any combination of these x compounds.

[0099] If present, the rheological modifier may be included in any suitable amount, for example, to achieve the desired viscosity, as understood by one of ordinary skill in the art. For example, in some embodiments, the rheology modifier is included in an amount of from about 0.01% to about 15% by weight of the wet composition, such as from about 0.01% to about 10%, from about 0.1% to about 5% from about 0.1% to about 3%, from about 0.1% to about 2%, or from about 0.1% to about 1%. Suture sealant usually contains from about 0.01% of the mass. to about 10% of the mass., from about 0.1% of the mass. up to about 5% of the mass. and / or from about 0.10% of the mass. up to about 3.0% of the mass. cellulose thickener. The alkyl group in suitable alkyl hydroxypropyl celluloses may contain up to 9 carbon atoms, but usually the alkyl group contains from one to three atoms. Hydroxypropyl methylcelluloses are often used, containing on average about two hydroxypropyl and / or methoxypropyl groups per anhydroglucose unit. The viscosity of an aqueous solution containing about 2% of the mass. a suitable hydroxypropyl cellulose alkyl ether at 20 ° C is from about 60,000 centipoise (cps) to about 90,000 cps, as measured on a Ubbelode capillary tube viscometer. Alternatively, a similar measurement can be performed on a Brookfield rotational viscometer at a speed of about 2.5 rpm to 5 rpm. In one of the modifications, the original solid-colored coating composition contains about 0.25% of the mass. hydroxypropyl cellulose alkyl ether. Undoubtedly, other types of cellulose thickeners can also be used, and a larger amount may be required when using a thickener with a lower viscosity (or vice versa). Typical hydroxypropyl cellulose alkyl ethers are sold under the trade name Methocel® (The Dow Chemical Company, MI).

[0100] Suitable associative thickeners for optional use in suture sealant compositions include hydrophobically modified ethoxylated urethanes (HEUR), hydrophobically modified alkaline swellable emulsions (HASE), and styrene maleic anhydride terpolymers (SMAT). HEUR thickeners (also commonly known as polyurethanes or PUR associative thickeners) can be incorporated into latex-based aqueous joint sealants and other liquid / solid yield strengths. Acidic acrylate copolymers (crosslinked) of ethyl acrylate and methacrylic acid, and acrylic terpolymers (crosslinked) of ethyl acrylate, methacrylic acid and a nonionic urethane surfactant monomer can also optionally be used as associative thickeners. When one or more suitable associative thickeners are used, the thickening reaction is caused in part by the association between the associative thickener and at least one suture sealant composition particle (e.g., a pigment particle or resin particle) or another associative thickener molecule. In various embodiments, the composition of the suture sealant may contain from about 0.01% of the mass. to about 10% of the mass., from about 0.1% of the mass. up to about 5.0% of the mass. and / or from about 0.1% of the mass. up to about 3% of the mass. associative thickener, if available. Suitable associative thickeners include thickeners sold under the trade name Alcogum® (Alco Chemical Company, Tennessee), under the trade name Acrysol® (Rohm & Haas, Pennsylvania), and under the trade name Viscalex® (Ciba Specialty Chemicals, NY) )

[0101] In one illustrative embodiment, the rheology modifier comprises HEUR and a cellulose ether, for example, alkyl hydroxypropyl cellulose ether. Not limited to any particular theory, it is believed that the combination of associative thickener and cellulose ether provides improved application and storage properties. For example, the sliding and flow characteristics of suture sealant compositions (when applied to a substrate) can be improved through the use of such a combination of associative thickener and cellulose ether. In addition, this combination can help protect the balls from settling in the suture sealant compositions (when storing the suture sealant compositions in bulk).

[0102] A system whose rheological characteristics are modified by introducing an associative thickener generally works best in an alkaline environment. Thus, it is generally recommended that base material be included in the suture sealant composition to impart a pH of at least 8.0 to the finished suture sealant composition. A number of different basic materials can be used to increase the pH, including, without limitation, ammonia, caustic soda (sodium hydroxide), triethylamine (TEA), and 2-amino-2-methyl-1-propanol (AMP). In various embodiments, the composition of the suture sealant contains from about 0.001% of the mass. to about 10% of the mass., from about 0.01% of the mass. up to about 0.5% of the mass. and / or from about 0.01% of the mass. up to about 0.50% of the mass. alkaline / base material.

[0103] In some embodiments, the suture sealant composition optionally contains a biocide in any suitable amount, for example, from about 0% to about 3% by weight of the wet composition, such as from about 0.05% to about 2%, from about 0.1% to about 1.5%, or from about 0.1% to about 1%. If, in some embodiments, the suture sealant composition is present, the biocide comprises a bactericidal agent and / or a fungicidal agent. An example of a suitable bactericidal agent is sold under the trade name MERGAL 174® (TROY Chemical Corporation). An example of a suitable fungicidal agent is sold under the trade name FUNGITROL® (International Specialty Products, NJ), or any combination of these agents.

[0104] The suture sealant composition may be made of any suitable viscosity to ensure manufacturability, as understood in the art. For example, the wet sealant composition viscosity can be from about 100 Brabender units (BU) to about 700 BU, such as from about 100 BU to about 600 BU, from about 100 BU to about 500 BU, from about 100 BU to about 400 BU, from about 100 BU to about 300 BU, from about 100 BU to about 200 BU, from about 130 BU to about 700 BU, from about 130 BU to about 600 BU, from about 130 BU to about 500 BU, from about 130 BU to about 400 BU, from about 130 BU to about 300 BU, from about 130 BU to about 200 BU, from about 150 BU to about 700 BU, from about 150 BU up to about 600 BU, from about 150 BU to about 500 BU, from about 150 BU to about 400 BU, from about 150 BU to about 300 BU, or from about 150 BU to about 200 BU. Brabender units are well understood by one of ordinary skill in the art. Viscosity is measured according to ASTM C474-05, Section 5, using a CW Brabender viscometer with a Type A needle, sample capacity 1/2 pint (236.6 cm ³ ), with a Brabender Torque-Head torsion block 250 cm-g, on speeds of 75 rpm.

[0105] Desirably, in some embodiments, to improve the antisettling properties of the composition seam sealant, to reduce the water content compared with conventional formulations. It is understood that some raw materials (e.g., latex emulsions and similar materials) are provided in aqueous form. However, in some embodiments, additional water (eg, mixing water) is desirably maintained at a low level, for example, in an amount of from about 60% or less by weight of the wet composition, for example, from about 0% to about 50%, such as from about 0% to about 30%, from about 0% to about 15%, or from about 0% to about 10%, etc. In some embodiments, the total water content of the joint sealant, including water from other raw materials, including latex emulsion binder, and any mixing water, may be in the range of, for example, from about 5% to about 60% by weight of the wet composition, such as from about 10% to about 45% by weight, or from about 25% to about 45% by weight, or more.

[0106] In some embodiments of the present invention, a suture sealant composition is provided, consisting essentially of (a) a latex emulsion binder in an amount of from about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow balls with an average isostatic crushing strength of at least about 100 psi, measured according to ASTM D3102-78, wherein the balls are present in an amount of from about 5% to about 25% by weight of the wet composition; (c) a nonionic surfactant in an amount of from about 0.001% to about 5% by weight of the wet composition; and (d) a humectant in an amount of from about 0.001% to about 3% by weight of the wet composition; and, optionally, (e) an antifoam in an amount of from about 0.05% to about 5% by weight of the wet composition; (f) a rheological modifier in an amount of from about 0.1% to about 5% by weight of the wet composition; (g) a biocide in an amount of from about 0.1% to about 1.5% by weight of the wet composition; (h) a bulking agent such as calcium carbonate or limestone in an amount of from about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of from about 0.1% to about 5% by weight of the wet composition. In such embodiments, the composition does not contain any raw material other than the above ingredients, which significantly affects the composition of the suture sealant according to the present invention.

[0107] According to embodiments of the present invention, there is also provided a wall structure in accordance with various aspects described herein. The wall structure contains two adjacent plates connected by a seam. In some embodiments, only one layer of suture sealant is applied over the seam to provide a uniform aesthetically pleasing appearance. However, if necessary, more than one coat (for example, two or three coats) can be applied, depending on the level of finish required. The suture sealant composition contains a binder selected from acrylic acid polymers, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds. The composition also contains many hollow balls. It is desirable that the balls have an average isostatic crush strength of at least about 100 psi, measured according to ASTM D3102-78. The wall structure further comprises a dimensionally stable, non-swellable flat tape for gluing the seams included in the seam.

[0108] According to embodiments of the present invention, there is also provided a method for processing a wall structure of two adjacent plates joined by a seam, according to various aspects described herein. In some embodiments, the method includes applying tape to the seam to seal the seams and one layer of the suture sealant composition. The suture sealant composition contains a binder selected from acrylic acid polymers, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds. The composition also contains many hollow balls. It is desirable that the balls have an average isostatic crush strength of at least about 100 psi, measured according to ASTM D3102-78. The method further includes drying the composition. In some embodiments, after applying and drying the joint sealant, the wall structure may be sanded and / or painted to obtain the desired appearance.

[0109] The following embodiments further illustrate aspects of the present invention, but should in no way be construed as limiting the scope of the invention.

[0110] In one embodiment, a drying type suture sealant composition comprises a binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxides, and combinations of these compounds; and a plurality of hollow balls, said balls having an average isostatic crushing strength of at least about 100 psi, measured according to ASTM D3102-78.

[0111] In another embodiment of the suture sealant composition, the binder is an acrylic acid polymer or an acrylic acid copolymer.

[0112] In another embodiment of the suture sealant composition, the binder is in the form of an aqueous emulsion.

[0113] In another embodiment of the suture sealant composition, the composition has a density of from about 2 f / gal. up to about 8 f / gal.

[0114] In another embodiment of the suture sealant composition, the composition has a shrink of about 2% or less, measured according to ASTM C474-05.

[0115] In another embodiment of the suture sealant composition, the composition is substantially free of setting minerals, bulk filler, clays, starch, mica, or a combination of these materials.

[0116] In another embodiment, the compositions of the suture sealant composition is substantially free of calcium carbonate, expanded perlite carbonate, magnesium calcium, limestone, calcium sulfate dihydrate, delaminirovannoy clays, such as kaolin clay, talc, diatomaceous earth, or combinations thereof.

[0117] In one embodiment, the suture sealant composition, the composition is substantially free of gelling clays. Such gel-forming clays include attapulgites, sepiolites, bentonites, laponites, nontronites, beidellites, yahontovites, zincites, volkonskoyites, hectorites, saponites, ferrosaponites, saukonites, swainfordites, pimelites, sookites, stevensmites, verbinsucci, smybucite, swindford montmorillonites, in particular sodium montmorillonite, magnesium montmorillonite and calcium montmorillonite, illites, mixed layered illite / smectite minerals, such as rectorites, tarosovites and icelites, aluminates oia magnesium, and mixtures of the above clays. Palygorskite attapulgite clays are one of the illustrative types of gelling clays that are excluded from this embodiment of the present invention.

[0118] In another embodiment of the suture sealant composition, the binder has a glass transition temperature (Tg) of from about 32 ° F (0 ° C) to about 70 ° F (21 ° C).

[0119] In another embodiment of the suture sealant composition, the binder has a minimum film formation temperature (MTP) of from about 32 ° F to about 90 ° F (32 ° C).

[0120] In another embodiment of the suture sealant composition, the balls have an average isostatic crush strength of at least about 250 psi (1724 kPa).

[0121] In another embodiment of the suture sealant composition, the balls have a density of from about 0.0015 f / in ³ (about 0.04 g / cm ³ ) to about 0.04 f / in ³ (about 1.1 g / cm ³ ).

[0122] In another embodiment of the suture sealant composition, the balls comprise calcareous borosilicate, polystyrene, ceramic material, recycled glass, foamed glass and light polyolefin granules, thermoplastic material, thermoset material, or any combination of these materials.

[0123] In another embodiment of the suture sealant composition, the composition further comprises a nonionic surfactant with a hydrophilic-lipophilic balance (HLB) of from about 3 to about 20.

[0124] In another embodiment, the suture sealant composition consists essentially of: (a) a latex emulsion binder in an amount of from about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow balls with an average isostatic crushing strength of at least about 100 psi (689 kPa), measured according to ASTM D3102-78, wherein the balls are present in an amount of from about 5% to about 25% by weight of the wet composition; (c) a nonionic surfactant in an amount of from about 0.001% to about 5% by weight of the wet composition; and (d) a humectant in an amount of from about 0.001% to about 3% by weight of the wet composition; and optionally: (e) an antifoam agent in an amount of from about 0.05% to about 5% by weight of the wet composition; (f) a rheological modifier in an amount of from about 0.1% to about 5% by weight of the wet composition; (g) a biocide in an amount of from about 0.1% to about 1.5% by weight of the wet composition; (h) a bulking agent such as calcium carbonate or limestone in an amount of from about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of from about 0.1% to about 5% by weight of the wet composition.

[0125] In another embodiment, the wall structure comprises: (a) two adjacent boards connected by a seam; (b) a single layer of suture sealant composition according to claim 1 in the seam to provide a uniform aesthetically pleasing appearance; and (c) dimensionally stable, non-swellable flat joint tape included in the seam.

[0126] In another embodiment of the wall structure, the at least one plate has a beveled edge adjacent to the seam, the maximum depth of the beveled edge being about 0.125 inches (about 0.3 cm) or less.

[0127] In another embodiment of the wall structure, the plates comprise opposite front and rear surfaces, the front surfaces of two adjacent plates being located relative to one another, forming an internal angle, with an angle between the front surfaces of the plates from about 30 ° to about 180 °.

[0128] In another embodiment of the wall structure of the slabs, opposed front and rear surfaces are provided, the front surfaces of two adjacent plates being located one relative to another, forming an outer angle, with an angle between the front surfaces of the plates from about 180 ° to about 300 °.

[0129] In another embodiment of the wall structure, the structure further comprises a reinforcing patch located over the seam, said patch comprising (i) a liner comprising paper having a dimensional stability of less than about 0.4% expansion in the machining direction and less than about 2.5% lateral expansion after immersion in water for 30 minutes, as measured according to ASTM C474-05 Section 12, and (ii) a reinforcing substrate containing paper, plastic, natural or synthetic fiber, carbon fiber, s false polyester, polycarbonate, fiberglass, non-woven natural or synthetic materials, woven natural or synthetic materials, spun polyolefin or metal, said substrate having a thickness of from about 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0, 2 cm).

[0130] In another embodiment of the wall structure, the structure comprises glue for at least partially attaching the reinforcing strip to the edges of the plate.

[0131] In another embodiment of the wall structure, the structure further comprises at least one carcass element and glue, said glue at least partially attaching at least one plate to the carcass element.

[0132] In another embodiment, a method for processing a wall structure comprising two adjacent plates connected by a seam is provided, said method comprising (a) applying a tape for gluing the seams and one layer of the joint sealant composition according to claim 1 to the joint; and (b) drying the composition.

[0133] In another embodiment, a reinforcing patch is proposed for protecting a seam between two adjacent plates that contain opposite front and back surfaces, the front surfaces being located relative to one another, forming an angle between the front surfaces of the plates, said patch comprising: a paper lining characterized by facing material from non-swellable synthetic paper; and a reinforcing substrate containing paper, thermoplastic material, thermosetting material, natural or synthetic fiber, carbon fiber, polyester, polycarbonate, fiberglass, nonwoven natural or synthetic materials, woven natural or synthetic materials, spun polyolefin or metal, said substrate having a thickness of from about 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0.2 cm).

[0134] In another embodiment, a drying type suture sealant composition comprises a binder selected from polymers of acrylic acid, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds; and a plurality of hollow balls, said balls having an average isostatic crushing strength of at least about 250 psi, measured according to ASTM D3102-78; and wherein the density of the beads is from about 0.0015 lb / ⁱⁿ³ (about 0.04 g / cm ³⁾ to about 0.04 lb / ⁱⁿ³ (about 1.1 g / cm ^3).

[0135] In another embodiment of the suture sealant composition, the balls have an average isostatic crush strength of at least about 500 psi.

[0136] In another embodiment of the suture sealant composition, the balls have a density of from about 0.0018 f / in ³ (≈ 0.05 g / cm ³ ) to about 0.036 f / in ³ (≈ 1 g / cm ³ ).

[0137] In another embodiment of the suture sealant composition, in a 3/16 inch (about 0.5 cm) strip, at least 60% of the water content is removed by drying for about 1.5 to 4.5 hours under moderate conditions at about 75 ° F (about 24 ° C) and about 50% relative humidity.

[0138] In another embodiment of the suture sealant composition, in a 3/16 inch (about 0.5 cm) strip, at least 60% of the water content is removed by drying for about 1 to about 3 hours in dry, hot conditions under about 95 ° F (approximately 35 ° C) and approximately 10% relative humidity.

[0139] In another embodiment of the suture sealant composition, in a 3/16 inch (about 0.5 cm) strip, at least 60% of the water content is removed by drying for about 5 to about 12.5 hours in cold, humid conditions at about 40 ° F (about 4 ° C) and about 80% relative humidity.

[0140] In another embodiment of the suture sealant composition, in a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed by drying for about 0.5 to 2 hours under moderate conditions under about 75 ° F (approximately 24 ° C) and approximately 50% relative humidity.

[0141] In another embodiment of the suture sealant composition, in a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed by drying for about 1 hour in dry, hot conditions at about 95 ° F ( approximately 35 ° C) and approximately 10% relative humidity.

[0142] In another embodiment, the suture sealant composition, in a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed by drying for about 0.5 to about 3 hours in cold, wet conditions at about 40 ° F (about 4 ° C) and about 80% relative humidity.

[0143] The following examples further illustrate the present invention, but, of course, should in no way limit the scope of the present invention.

EXAMPLE 1

[0144] In the present example, three sample compositions (1A, 1B, and 1C) are shown illustrating a joint sealant according to embodiments of the present invention.

[0145] As an illustrative preparation method, all liquid ingredients were placed in a Model N50 Hobart mixer. It should be noted here that only functional filler (Scotchlite K1) and rheological polymer (Cellosize DSC) were dry materials, while the remaining components were considered liquid from the point of view of introduction into the mixer. Since the functional filler was in bulk, and the rheological polymer was taken in small quantities, the rheological polymer was added to the functional filler, and the combined dry material was introduced into a mixer already containing liquid. The resulting composition was mixed for approximately 2 minutes until uniform.

[0146] However, it is understood that the compositions can be prepared in any suitable way. For example, the composition can be obtained on a factory scale in a mixer with a horizontal blade shaft with a spiral arrangement of blades, or in a similar way to achieve the desired mixing dynamics, as is clear to the average person skilled in the art.

[0147] Composition 1A is shown in table 1 below. It is understood that “introduced water” refers to additional water other than already contained in any ingredients (for example, RHOPLEX is in the form of an emulsion with a mass ratio of solids / water 47/53).

Table 1

Composition 1A Ingredient type of mass (f) mass% Polyacrylate ester emulsion
(RHOPLEX E-330 ™)
Rohm & Haas (UK) astringent 700 71.6% Oil distillate
(Bubreak 4412 ™)
Buckman Laboratories (Memphis, TN) antifoam four 0.4% Octylphenol Ethoxylate
(TRITON X-405 ™)
The Dow Chemical Company (Midland, MI) Surface-active substance 2 0.2% Bubbles of Sodium-Lime Borosilicate Glass
(SCOTCHLITE K1 ™)
3M (St. Paul, MN) Functional filler 150 15.3% 2 ((hydroxymethyl) amino) ethanol
(MERGAL 174 ™)
Troy Chemical Corporation (Florham Park, NJ) biocide one 0.1% Tributyltin Benzoate
(FUNGITROL 158 ™)
International Specialty Products (Wayne, NJ) biocide one 0.1% ethylene glycol
ME Global (Dubai, United Arab Emirates) humidifier fifteen 1.5% hydroxyethyl cellulose
(Cellosize DSC ™)
The Dow Chemical Company (Midland, MI) Rheological polymer 5 0.5% methyl acrylate emulsion copolymer
(Alcogum L-62 ™)
Akzo Nobel (Amsterdam, Netherlands) Rheological modifier 0 0,0% Water introduced one hundred 10.2% Total 978 100.0%

[0148] Composition 1B is shown in table 2 below.

table 2

Composition 1B Ingredient type of mass (f) mass% Polyacrylate ester emulsion
(RHOPLEX E-330 ™)
Rohm & Haas (UK) astringent 900 83.8% Oil distillate
(Bubreak 4412 ™)
Buckman Laboratories (Memphis, TN) antifoam 0 0,0% Octylphenol Ethoxylate
(TRITON X-405 ™)
The Dow Chemical Company (Midland, MI) Surface-active substance 2 0.2% Bubbles of Sodium-Lime Borosilicate Glass
(SCOTCHLITE K1 ™)
3M (St. Paul, MN) Functional filler 150 14.0% 2 ((hydroxymethyl) amino) ethanol
(MERGAL 174 ™)
Troy Chemical Corporation (Florham Park, NJ) biocide one 0.1% Tributyltin Benzoate
(FUNGITROL 158 ™)
International Specialty Products (Wayne, NJ) biocide one 0.1% ethylene glycol
ME Global (Dubai, United Arab Emirates) humidifier fifteen 1.4% hydroxyethyl cellulose
(Cellosize DSC ™)
The Dow Chemical Company (Midland, MI) Rheological polymer 5 0.5% methyl acrylate emulsion copolymer
(Alcogum L-62 ™)
Akzo Nobel (Amsterdam, Netherlands) Rheological modifier 0 0,0% Water introduced 0 0,0% Total 1074 100.0%

[0149] Composition 1C is shown in table 3 below.

Table 3

Composition 1C Ingredient type of mass (f) mass% Polyacrylate ester emulsion
(RHOPLEX E-330 ™)
Rohm & Haas (UK) astringent 800 74.3% Oil distillate
(Bubreak 4412 ™)
Buckman Laboratories (Memphis, TN) antifoam 3 0.3% Octylphenol Ethoxylate
(TRITON X-405 ™)
The Dow Chemical Company (Midland, MI) Surface-active substance 2 0.2% Bubbles of Sodium-Lime Borosilicate Glass
(SCOTCHLITE K1 ™)
3M (St. Paul, MN) Functional filler 150 13.9% 2 ((hydroxymethyl) amino) ethanol
(MERGAL 174 ™)
Troy Chemical Corporation (Florham Park, NJ) biocide one 0.1% Tributyltin Benzoate
(FUNGITROL 158 ™)
International Specialty Products (Wayne, NJ) biocide one 0.1% Ethylene glycol
ME Global (Dubai, United Arab Emirates) humidifier fifteen 1.4% hydroxyethyl cellulose
(Cellosize DSC ™)
The Dow Chemical Company (Midland, MI) Rheological polymer 2 0.2% methyl acrylate emulsion copolymer
(Alcogum L-62 ™)
Akzo Nobel (Amsterdam, Netherlands) Rheological modifier 6 0.6% Water introduced 97 9.0% Total 1077 100.0%

[0150] The compositions shown in table 1 included a relatively small amount of water, resulting in low levels of shrinkage, while also observed good compressive strength and bending strength. These compositions were easily applied in a smaller number of layers than in conventional systems (for example, preferably in a system with a single layer), on the seams, linings and fasteners in wall structures according to some embodiments of the present invention. As a result, 1A-1C formulations provided effective application without noticeable delays requiring a waiting time for each individual coat to dry. Compositions 1A-1C also provided the possibility of easy application, requiring less skill on the part of the user, since these compositions can be applied closer to the plane of the wall structures. Compositions 1A-1C showed shrinkage from about zero to about 3%, measured according to ASTM C474-05, section 6. In addition, compositions 1A-1C showed crack resistance when tested according to ASTM C474-05, section 7.

EXAMPLE 2

[0151] This example illustrates the superior strength properties of a joint sealant in accordance with embodiments of the present invention compared to two different conventional joint joints.

[0152] Only three samples were tested for flexural strength. Each suture sealant sample was prepared and dried in the form of a strip 10 inches long (about 25 cm), 2 inches wide (about 5 cm) and 0.0625 inches thick (about 0.2 cm). Each sample was placed on a table, placing the ends of the sample on supports 0.125 (1/8) inches thick (about 0.3 cm) to demonstrate, at the slightest displacement, the brittleness and brittleness associated with typical samples of commercial suture sealant product formulations used in industry. A downward force of approximately 200 grams was applied to the center of each of the suture sealant strips using a metal sensor.

[0153] For comparison purposes, the first sample, composition 2A, was a conventional suture sealant, commercially available as SHEETROCK® Brand, a lightweight multi-purpose suture sealant from USG, with a density of approximately 14 psi. (1680 kg / m ³ ). The test progress is shown in FIG. 19-21. As can be seen in FIG. 21, the suture sealant collapsed with a deflection of less than 1/8 inch, thus showing the brittle nature of the sample.

[0154] For purposes of further comparison, the second sample, composition 2B, was another conventional suture sealant, commercially available as SHEETROCK® Brand, a multi-purpose suture sealant from USG, with a density of approximately 8 psi. (960 kg / m ³ ). The test progress is shown in FIG. 22-24. As can be seen in FIG. 24, the suture sealant collapsed with a deflection of less than 1/8 inch, thus showing the brittle nature of the sample.

[0155] A third composition, 2C, was prepared according to composition 1A, as shown in Table 1, according to embodiments of the present invention. Composition 2C had a density of 3 f / gal. (360 kg / m ³ ). The test progress is shown in FIG. 25-27. As can be seen in FIG. 27, after 1/8 inch deflection, the sample did not break (in contrast to comparative compositions 2A and 2B). In addition, as can be seen in FIG. 28, the 2C composition did not crack or break even with a larger deflection. Indeed, even when the 2C sample was bent in a loop, as can be seen in FIG. 29, the specimen did not crack or collapse.

[0156] It is understood that composition 2C confers the most desirable finishing properties to dry joint plaster. For example, 2C does not shrink when dry. In addition, 2C retains sufficient flexibility to resist cracking (as opposed to the conventional brittle compositions shown in 2A and 2B), while remaining stiff enough to allow easy sanding and smoothing. Composition 2C can also be easily painted.

EXAMPLE 3

[0157] The present example shows a set of five rows of formulations (2D-F, 3A-C, 4A-C, 5A-C and 6A-C) illustrating a joint sealant according to embodiments of the present invention.

[0158] It is understood that the compositions can be prepared by any suitable method, for example, as described in Example 1. For example, the composition can be obtained on a factory scale in a mixer with a horizontal blade shaft with a spiral arrangement of blades, or in a similar way to achieve the desired mixing dynamics, such as understood by one of ordinary skill in the art.

[0159] It is understood that “introduced water” refers to additional water other than already contained in any ingredients.

Table 4

Composition 2 D E F ingredient type of mass (f) mass% mass (f) mass% mass (f) mass% Rhoplex MC-1834P astringent 300,0 46.8 160,0 26.2 200,0 37.1 Oil distillate
(Bubreak 4412 ™)
Buckman Laboratories (Memphis, TN) antifoam 2.0 0.3 2.0 0.3 2.0 0.4 Octylphenol Ethoxylate
(TRITON X-405 ™)
The Dow Chemical Company (Midland, MI) Surface-active substance 0.5 0.1 2.1 0.3 0.5 0.1 Bubbles of Sodium-Lime Borosilicate Glass
(SCOTCHLITE K1 ™)
3M (St. Paul, MN) Functional filler 160,0 25.0 160,0 26.2 160,0 29.7 2 ((hydroxymethyl) amino) ethanol
(MERGAL 174 ™)
Troy Chemical Corporation (Florham Park, NJ) biocide 2.0 0.3 2.0 0.3 2.0 0.4 ethylene glycol
ME Global (Dubai, United Arab Emirates) humidifier 15.0 2,3 15.0 2.5 15.0 2,8 hydroxyethyl cellulose
(Cellosize DSC ™)
The Dow Chemical Company (Midland, MI) Rheological polymer 5,0 0.8 3.0 0.5 3.0 0.6 Alcogum L-62 Rheological modifier 6.0 0.9 6.0 1,0 6.0 1,1 Water introduced 150.0 23,4 260,0 42.6 150.0 27.9 Total 640.5 100.0 610.1 100.0 538.5 100.0

Table 5

Composition 3 A B C ingredient type of mass (f) mass% mass (f) mass% mass (f) mass% Rhoplex MC-1834P astringent 200,0 7.4 300,0 13.9 300,0 14.0 Bubreak 4412 antifoam 4.0 0.1 0,0 0,0 0,0 0,0 Bubreak 4419 antifoam 0,0 0,0 4.0 0.2 4.0 0.2 Scotchlite K1 Functional filler 100.0 3,7 250,0 11.6 400,0 18.7 Scotchlite iM16K Functional filler 400,0 14.8 250,0 11.6 100.0 4.7 Microwhite 100 Calcium Carbonate filler 1000,0 36.9 500,0 23,2 500,0 23.3 Mergal 174 II biocide 2.0 0.1 2.0 0.1 2.0 0.1 ethylene glycol humidifier 0,0 0,0 0,0 0,0 15.0 0.7 sorbitol humidifier 10.0 0.4 15.0 0.7 0,0 0,0 Actimin kaolin clay Rheological modifier 50,0 1.8 10.0 0.5 1,0 0,0 Cellosize DCS Rheological polymer 10.0 0.4 10.0 0.5 10.0 0.5 Alcogum L-62 Rheological modifier 0,0 0,0 6.0 0.3 6.0 0.3 Minugel fg Rheological modifier 35.0 1.3 6.0 0.3 6.0 0.3 Water 900.0 33,2 800,0 37,2 800,0 37.3 Total 2711.0 100.0 2153 100.0 2144.0 100.0

Table 6

Composition 4 A B C Ingredient type of mass (f) mass% mass (f) mass% mass (f) mass% Rhoplex MC-1834P astringent 600,0 26.0 900.0 39.8 300,0 13,2 Bubreak 4419 antifoam 4.0 0.2 4.0 0.2 4.0 0.2 Scotchlite K1 Functional filler 100.0 4.3 100.0 4.4 100.0 4.4 Scotchlite iM16K Functional filler 400,0 17.3 400,0 17.7 400,0 17.5 Microwhite 100 Calcium Carbonate filler 700,0 30.3 700,0 31,0 700,0 30.7 Mergal 174 II biocide 2.0 0.1 2.0 0.1 2.0 0.1 sorbitol humidifier 10.0 0.4 10.0 0.4 10.0 0.4 Actimin kaolin clay Rheological modifier 50,0 2.2 0,0 0,0 20,0 0.9 Cellosize DCS Rheological polymer 10.0 0.4 10.0 0.4 10.0 0.4 Minugel fg Rheological modifier 35.0 1,5 35.0 1,5 35.0 1,5 water 400,0 17.3 100.0 4.4 700,0 30.7 total 2311.0 100.0 2261 100.0 2281.0 100.0

Table 7

Composition 5 A B C ingredient type of mass (f) mass% mass (f) mass% mass (f) mass% Rhoplex MC-1834P astringent 600,0 26.3 900.0 40,4 300,0 13.3 Bubreak 4419 antifoam 4.0 0.2 4.0 0.2 4.0 0.2 Scotchlite S15 Functional filler 100.0 4.4 250,0 11,2 400,0 17.8 Scotchlite iM30K Functional filler 400,0 17.5 250,0 11,2 100.0 4.4 Microwhite 100 Calcium Carbonate filler 700,0 30.7 700,0 31,4 400,0 17.8 Minex 7 filler 0,0 0,0 0,0 0,0 300,0 13.3 Mergal 174 II biocide 2.0 0.1 2.0 0.1 2.0 0.1 sorbitol humidifier 10.0 0.4 10.0 0.4 10.0 0.4 Actimin kaolin clay Rheological modifier 50,0 2.2 0,0 0,0 20,0 0.9 Cellosize DCS Rheological polymer 10.0 0.4 10.0 0.4 10.0 0.4 Alcogum L-62 Rheological modifier 6.0 0.3 3.0 0.1 3.0 0.1 water 400,0 17.5 100.0 4,5 700,0 31.1 total 2282.0 100.0 2229 100.0 2249.0 100.0

Table 8

Composition 6 A B C ingredient type of mass (f) mass% mass (f) mass% mass (f) mass% Rhoplex MC-1834P astringent 600,0 48.7 900.0 73,2 300,0 19.6 Bubreak 4419 antifoam 4.0 0.3 4.0 0.3 4.0 0.3 Scotchlite K1 Functional filler 100.0 8.1 150.0 12,2 400,0 26.2 Scotchlite iM30K Functional filler 400,0 32,5 150.0 12,2 100.0 6.5 Mergal 174 II biocide 2.0 0.2 2.0 0.2 2.0 0.1 sorbitol humidifier 10.0 0.8 10.0 0.8 10.0 0.7 Cellosize DCS Rheological polymer 10.0 0.8 10.0 0.8 10.0 0.7 Alcogum L-62 Rheological modifier 6.0 0.5 3.0 0.2 3.0 0.2 water 100.0 8.1 0,0 0,0 700,0 45.8 total 1232.0 100.0 1229 100.0 1529.0 100.0

EXAMPLE 4

[0160] The following example illustrates the superior flexibility, crack resistance, and strength compared to commercially available suture sealants when used in the new joint system and test according to ASTM C474.

[0161] Formulations 1A and 2E were prepared as described above. Also, for comparison purposes, a conventional multi-purpose suture sealant (composition AP) and a light multi-purpose suture sealant (composition LW) were used. The AP formulation was SHEETROCK® Brand, a multi-purpose suture sealant, and the LW formulation was SHEETROCK® Brand, a lightweight multipurpose suture sealant. Each sample was prepared in triplicate.

[0162] Each formulation was prepared and tested according to ASTM C474 as follows. Suture sealants were applied to the gap formed in the seam of the gypsum board using a waxed separator. On top of the connection of the gypsum panels, a synthetic tape was fixed for gluing the seams. Samples were applied over the tape and held for 24 hours at 70 ° F (approximately 21 ° C) and 50% relative humidity. Wax separators were removed and samples were mounted on test benches. The stands were placed in a universal test setup (UTM).

[0163] Each joint system was subjected to a load of 0.4 inches / min (about 1 cm / min) at a constant displacement rate until the sample broke. The load and displacement were recorded twice - first, before the appearance of a visible crack, and a second time before the destruction of the system.

[0164] FIG. 30-34 show the superiority of formulations 1A and 2E over comparative formulations AP and LW under test conditions.

[0165] FIG. 30 is a box diagram showing the displacement under pressure when the first crack, measured in inches, along the Y axis, and various joint sealants along the X axis, namely, compositions 1A and 2E according to embodiments of the present invention and compositions AP and LW in as comparative examples. The diagram shows that for compounds 1A and 2E, the displacement was approximately 0.12 inches (approximately 0.3 cm) before the first crack appeared. On the other hand, the first crack was observed for the AP composition at 0.06 inches (about 0.15 cm), and for the LW composition, the first crack was observed at 0.08 inches (about 0.2 cm). It is also worth noting that compositions 1A and 2E did not produce visible cracks during displacement. They showed cracks only after the destruction and removal of the underlying tape for sealing joints. So, compositions 1A and 2E showed significantly greater crack resistance compared to commercially available sealants, compositions AP and LW.

[0166] FIG. 31 is a box diagram showing the load (in pounds) when the first crack, measured in pounds (f), along the Y axis, and various joint sealants along the X axis, namely compositions 1A and 2E according to embodiments of the present invention, and AP and LW formulations as comparative examples. The diagram shows that compositions 1A and 2E could withstand 124 lb (approximately 56 kg) and 95 lb (approximately 43 kg), respectively, before the first crack occurred. On the other hand, the first crack in the composition of the AP was observed at a load of 53 ft (approximately 24 kg), and the first crack in the composition of LW was observed at a load of 60 ft (approximately 27 kg). It is also worth noting that compositions 1A and 2E did not produce visible cracks during displacement. They showed cracks only after the destruction and removal of the underlying tape for sealing joints. So, compositions 1A and 2E showed significantly greater crack resistance and could withstand a significantly higher load before failure, compared with commercially available sealants, AP and LW compounds.

[0167] FIG. 32 is a box diagram showing shear displacement when the first crack, measured in inches, along the Y axis, and various joint sealants along the X axis, namely, compositions 1A and 2E according to embodiments of the present invention and compositions AP and LW in as comparative examples. The diagram shows that for compounds 1A and 2E, the displacement was approximately 0.11 and 0.12 inches (approximately 0.3 cm), respectively, before the first crack appeared. On the other hand, the first crack was observed for the AP composition at 0.08 inches (about 0.2 cm), and for the LW composition, the first crack was observed at 0.11 inches (about 0.3 cm). It is also worth noting that compositions 1A and 2E did not produce visible cracks during displacement. They showed cracks only after the destruction and removal of the underlying tape for sealing joints. Thus, a wide range of data was observed for compositions 1A and 2E. Nevertheless, the AP and LW compounds apparently cracked / broke long before the destruction of the tape for sealing the seams and the seam. So, compositions 1A and 2E showed significantly greater shear resistance to shear as compared to commercially available sealants, AP and LW.

[0168] FIG. 33 is a box diagram showing peak shear displacement when the first crack, measured in inches, along the Y axis, and various joint sealants along the X axis, namely compositions 1A and 2E according to embodiments of the present invention and compositions AP and LW, were observed. as comparative examples. The diagram shows that the peak shear displacement for compositions 1A and 2E was 0.23 inches (about 0.6 cm) and 0.25 inches (about 0.6 cm), respectively, before the first crack occurred. On the other hand, the first crack in the composition of the AP was observed after a peak displacement at a shear of 0.1 inches (about 0.25 cm), and the first crack in the composition of LW was observed after a peak displacement at a shear of 0.13 inches (about 0.3 cm) . It is also worth noting that compositions 1A and 2E did not produce visible cracks during displacement. They showed cracks only after the destruction and removal of the underlying tape for sealing joints. So, the compositions 1A and 2E showed a significantly greater peak shift in shear, compared with commercially available sealants, compositions AP and LW.

[0169] FIG. 34 is a box diagram showing the ratio of the shear displacement (i.e., the ratio of the maximum displacement upon failure of the joint system to the displacement at the time of the first crack) along the Y axis and various joint sealants along the X axis, namely, compositions 1A and 2E according to embodiments of the present invention and the compositions of AP and LW as comparative examples. The diagram shows that the compositions 1A and 2E had a displacement ratio of about 2.3 before the first crack, while the AP composition had a displacement ratio of about 1.3, and the LW composition had a displacement ratio of 1.2. Thus, compositions 1A and 2E showed greater elongation and tensile properties, even after the formation of the first crack, until complete failure was achieved by rupture in the joint system. It is also worth noting that compositions 1A and 2E did not produce visible cracks during displacement. They showed cracks only after the destruction and removal of the underlying tape for sealing joints. On the other hand, the sealants of the AP and LW compositions were brittle materials and showed peak displacement shortly after the formation of the first visible crack.

[0170] The results obtained in the present example showed that when the joint system was stretched, both compositions 1A and 2E showed excellent elongation and physical displacement to fracture, while the compositions AP and LW were brittle and did not have similar characteristics in those the same test conditions of the compound system of the present invention Also, these commercially available suture sealants have shown no advantage in conventional joint systems.

[0171] When the joint systems of the present invention were subjected to shear, the differences between the joint sealants of the present invention and conventional joint sealants became even more noticeable. Suture sealants in the present example showed superior offsets and higher offset ratios than commercially available suture sealants. So, the suture sealants according to the present invention showed high strength and crack resistance.

EXAMPLE 5

[0172] This example illustrates excellent flexibility and elastomeric properties or flexibility / brittleness when used in a new joint system and test according to ASTM C711.

[0173] Each of the formulations was prepared and tested according to ASTM C711 as follows. Compositions 1A and 2E were prepared and commercially available suture sealants AP-SHEETROCK® Brand, a multi-purpose suture sealant, and LW-SHEETROCK® Brand, a lightweight multi-purpose suture sealant, were used for comparison purposes. Each sample was prepared in triplicate.

[0174] A strip of suture sealant (2 ”x 10”) (about 5 cm x about 25 cm) with a thickness of 1/8 inch (about 0.3 cm) was placed on a non-stick film, i.e. suture sealant did not stick to the film after drying. Samples were prepared in triplicate for each test condition. The samples were then dried under four different test conditions for 24 hours. The second round of tests was carried out after storage for 28 days. Samples were removed from a non-stick film and placed under bending conditions around a 1 inch (about 2.5 cm) diameter cylindrical core to evaluate the elastomeric and flexible properties of suture sealants. Samples were then visually evaluated on a 3-point scale to determine the degree of elastomeric flexibility properties according to ASTM C711.

[0175] It should be noted that the ASTM C711 standard published in 2009, using photographs, illustrates the differences between a satisfactory suture sealant and an unsatisfactory suture sealant when attaching and wrapping around the core according to the test. One of the photographs shows a satisfactory joint sealant that passed the test without cracks or any visible damage. The other shows an unsatisfactory suture sealant that has been rated unfit-A due to several cracks. The third shows an unsatisfactory suture sealant that has been rated unfit-B due to complete failure and loss of adhesion.

Table 9

FLEXIBILITY TEST RESULTS - ASTM C711

24 hours
conditions 1A 2E AP Lw 40 ° F / 80% RH
cold / wet Passed Passed Not fit-B Not fit-B 75 ° F-50% RH
standard / room Passed Passed Not fit-B Not fit-B 95 ° F / 10% RH
hot / dry Passed Passed Not fit-B Not fit-B 90 ° F / 90% RH
hot / humid Passed Passed Not fit-B Not fit-B

Table 10

FLEXIBILITY TEST RESULTS - ASTM C711

28 days
conditions 1A 2E AP Lw 40 ° F / 80% RH
cold / wet Passed Passed Not fit-B Not fit-B 75 ° F-50% RH
standard / room Passed Passed Not fit-B Not fit-B 95 ° F / 10% RH
hot / dry Passed Passed Not fit-B Not fit-B 90 ° F / 90% RH
hot / humid Passed Passed Not fit-B Not fit-B

[0176] Table 9 shows the results of a visual evaluation after holding the samples under four different conditions according to ASTM C711 for 24 hours. Samples of compositions 1A and 2E showed significantly better behavior compared to conventional suture sealants represented by compositions AP and LW. While formulations 1A and 2E received a grade of “passed” for each of the standard test conditions, formulations AP and LW received a score of unfit-B.

[0177] Table 10 shows the results of a visual evaluation after holding the samples under four different conditions according to ASTM C711 for 28 days. Samples of compositions 1A and 2E showed significantly better behavior compared to conventional suture sealants represented by compositions AP and LW. While formulations 1A and 2E received a grade of “passed” for each of the standard test conditions, formulations AP and LW received a score of unfit-B.

[0178] Conventional suture sealants in the conditions of this test were so brittle that they collapsed even when bent by less than 1/8 inch, and could not be wrapped around a cylindrical core without complete destruction. The behavior of the joint sealant under the conditions of this test helps to ensure structural compliance and the service life of the joint sealants.

EXAMPLE 6

[0179] The following example illustrates the excellent properties of joint sealants and joint systems in real-world conditions representing operating conditions. The performance criteria were based on test data that guaranteed the structural consistency of suture sealants and joint systems throughout their service life.

[0180] The compound system of the present invention and the conventional compound system were tested according to a modified ASTM E72 as follows. A wall joint system according to the present invention was prepared using formulations 1A and 2E, and compared with formulations AP and LW. Samples of formulations 1A and 2E were prepared and typical commercially available joint sealants AP-SHEETROCK® Brand, a multi-purpose joint sealant, and LW-SHEETROCK® Brand, a lightweight multi-purpose joint sealant, were used for comparison purposes. The composition of the AP was a conventional multi-purpose suture sealant. LW was a lightweight multi-purpose joint sealant.

[0181] Compositions 1A and 2E were used to prepare the test under conditions of flat seam processing (square edge / butt and beveled joints). In this system, the seams were glued with synthetic reinforcing tape for gluing seams for fastening the joined plates with glue. One layer of composition 1A or 2E was applied over the glued joints. Fasteners were prepared by applying one layer of suture sealant according to the present invention of composition 1A or 2E over the fasteners.

[0182] For comparison, a conventional joint system was prepared by gluing all flat joint seams with paper reinforcing tape attached to the joint plate using a joint sealant of AP or LW composition. Three (3) separate layers of AP or LW suture sealant were applied over glued joint seams. Fasteners were prepared by applying three (3) separate layers of suture sealant of the AP or LW formulations over the fasteners.

[0183] FIG. 35A - 35C show a modified ASTM E72 framework design for testing the strength of a wall in a building structure.

[00100] FIG. 35A shows a modified ASTM E72 frame construction of a size of 8 'x 8' (about 2.4 mx about 2.4 m) with a frame made of 2 ”x 4” wood blocks (about 5 cm x about 10 cm). Wooden bars are not shown. The design consists of two 48 ”x 64” slabs (approximately 1.2 mx approximately 1.6 m) and two 48 ”x 16” slabs (approximately 1.2 m x approximately 0.4 m) in a reverse configuration. The two main seams are shown by dashed lines - a horizontal joint at half height (about 4 'or about 1.2 m) and two vertical joints located at the junction of two plates.

[00101] FIG. 35B shows a modified ASTM E72 frame design with FIG. 35A, equipped with 2 ”x 4” wooden blocks spaced about 16 inches apart (about 0.4 meters). Two seams are also shown - a horizontal joint at half height (about 4 'or about 1.2 m) and two vertical joints located at the junction of two plates joined to wooden blocks.

[00102] FIG. 35C shows a modified ASTM E72 frame design with FIG. 35B, the bottom of which is rigidly attached to the structure, and a force is applied to the upper left corner using a hydraulic piston programmed to move along a sinusoidal path with a variable amplitude.

[0184] In the present test, the plane of the slab in the described frame structure can only move in the same plane with the face of the wall. A computer-controlled hydraulic piston is programmed to move along a sinusoidal path with an amplitude of 0.025 ”(approximately 0.06 cm) and a frequency of 0.5 Hz (2 seconds per cycle) for 500 cycles, and had a hammer in the upper left corner of the structure. After the end of the cycle, the amplitude was increased to 0.050 ”(about 0.12 cm) for 500 cycles. After the second cycle, the amplitude was again increased to 0.075 ”(about 0.18 cm) over 500 cycles. The described procedure was repeated until an amplitude of 0.400 ”(approximately 1 cm) was reached. In the course of the described rigidity test, the structure was continuously monitored, and when failure occurred, the cycle number and the place of failure were noted.

[0185] The results showed a significant advantage of the elastic membrane effect in formulations 1A and 2E. Even in those places where the fasteners were torn off the wall structure, the joint sealant was not torn or punctured. At the same time, in a comparative conventional system made using conventional suture sealants, for example, AP and LW compositions, the effect of brittle fracture was observed, including loss of binding in place over the fasteners.

EXAMPLE 7

[0186] The following example illustrates the excellent drying properties of the compound system of the present invention.

[0187] As discussed in the description, existing suture sealants require applying three separate layers to the fasteners, as well as applying multiple layers to the flat seams between the plates in the same plane. Each coat must dry separately before applying a new coat. In this case, although the existing coating should not dry completely, it was found that approximately 75% of the water content should evaporate from the compound until the coating becomes dense enough to apply a second layer. This creates a significant period of downtime during which other construction workers usually cannot work inside the building until the walls are finished.

[0188] On the other hand, the suture sealant according to the present invention requires only one layer over the seam to provide a uniform aesthetically pleasing appearance. In the event that a second layer is necessary, taking into account the imperfection of qualifications and similar reasons, the suture sealant according to the present invention becomes sufficiently dense to apply the second layer by evaporating about 60% of the water from the sealant.

[0189] Samples of compositions 1A, 2E, 3A, and 4B were prepared. Also, for comparison purposes, a conventional multi-purpose suture sealant (composition AP) and a light multi-purpose suture sealant (composition LW) were used. The AP formulation was SHEETROCK® Brand, a multi-purpose suture sealant, and the LW formulation was SHEETROCK® Brand, a lightweight multipurpose suture sealant.

[0190] In FIG. 36A - 36C show a drying profile of suture sealants according to the present invention, compared with conventional suture sealants, for a thick coating layer, i.e. about 3/16 inch (about 0.5 cm), which shows the percentage of evaporated water (Y axis), depending on the increasing drying time represented by the X axis. In FIG. 36A shows mild drying profiles, for example 75 ° F (24 ° C) and 50% relative humidity. In FIG. 36B shows drying profiles in hot and dry conditions, for example 95 ° F (35 ° C) and 10% relative humidity. In FIG. 36C shows drying profiles in cold wet conditions, for example, 40 ° F (4.4 ° C) and 80% relative humidity.

[0191] A thick layer (3/16 inch, about 0.5 cm) is typical for various applications, for example, 1st or 2nd coating over an angular reinforcement strip; 1st or 2nd coating over the edges of the panel / wall; 1st or 2nd coating over butt joints with square edges; and a 2nd fill coating over joints with beveled edges.

[0192] As can be seen in FIG. 36A, 3/16 inch (about 0.5 cm) coatings of formulations 1A, 2E, 3A, and 4B show similar mild drying profiles. If you need a second layer, the first layer of compositions 1A, 2E, 3A and 4B would be ready within 1.5 to 4.5 hours. On the other hand, a thick layer of LW composition would be ready to apply a second layer in about 13 to 15 hours, while a thick layer of AP composition would not be ready even after 24 hours.

[0193] As can be seen in FIG. 36B, 3/16 inch (about 0.5 cm) coatings of formulations 1A, 2E, 3A, and 4B show similar drying profiles in a dry, hot environment. If you need a second layer, the first layer of compositions 1A, 2E, 3A and 4B would be ready within 1 to 3 hours. On the other hand, a thick layer of the LW and AP compositions would be ready for application of the second layer within about 4 to 5.5 hours.

[0194] As can be seen in FIG. 36C, 3/16 inch (about 0.5 cm) thick coatings of formulations 2E and 4B show the fastest drying times in a cold humid environment, followed by formulations 1A and 3A. If you need a second layer, the first layer of compositions 1A, 2E, 3A and 4B would be ready within 5 to 12.5 hours. On the other hand, a thick layer of LW and AP would not be ready even after 24 hours.

[0195] In FIG. 37A-37C show the drying profile of suture sealants according to the present invention compared to conventional suture sealants for a thin coating layer, i.e. about 1/16 inch (about 0.2 cm), which shows the percentage of evaporated water (Y axis), depending on the increasing drying time represented by the X axis. FIG. 37A shows mild drying profiles, for example, 75 ° F (24 ° C) and 50% relative humidity. In FIG. 37B shows drying profiles in hot and dry conditions, for example 95 ° F (35 ° C) and 10% relative humidity. In FIG. 37C shows drying profiles in cold wet conditions, for example 40 ° F (4.4 ° C) and 80% relative humidity.

[0196] A thin layer (1/16 inch, about 0.2 cm) is typical for various applications, for example, 1st or 2nd coating over the inner corner finish; 1st, 2nd or 3rd finishing coating on top of flat joints; 3rd coating over butt joints with square edges; and 1st, 2nd or 3rd coating over fasteners.

[0197] As can be seen in FIG. 37A, 1/16 inch (about 0.2 cm) coatings of formulations 1A, 2E, 3A, and 4B show similar moderate drying profiles. If you need a second layer, the first layer of compositions 1A, 2E, 3A and 4B would be ready within 0.5 to less than 2 hours. On the other hand, thin layers of the LW and AP compositions would be ready to apply the second layer in about 3.5 to 10 hours.

[0198] As can be seen in FIG. 37B, 1/16 inch (about 0.2 cm) coatings of formulations 1A, 2E, 3A, and 4B show similar drying profiles in a dry, hot environment. If a second layer was needed, the first layer of formulations 1A, 2E, 3A and 4B would be ready in about 1 hour. On the other hand, thin layers of the LW and AP compositions would be ready to apply the second layer in about 1.5 to more than 2 hours.

[0199] As can be seen in FIG. 37C, 1/16 inch (about 0.2 cm) coatings of formulations 1A, 2E, 3A, and 4B show similar drying times in a cold, humid environment. If a second layer was needed, the first layer of formulations 1A, 2E, 3A and 4B would be ready in about 0.5 to less than 3 hours. On the other hand, a thin layer of the LW and AP compositions would be ready to apply the second layer in about 7 to more than 10 hours.

[0200] Therefore, the present example shows that the suture sealants according to the present invention have faster drying profiles in each test under different test conditions than conventional suture sealants.

[0201] The use of the terms in the singular and “at least one” and similar indications in the context of the description of the present invention (especially in the context of the following claims) should be construed as including the singular and plural, unless otherwise indicated or explicitly prescribed context. The use of the term “at least one” followed by a list of one or more items (eg, “at least one of A and B”) should be construed as including any one item selected from the listed items (A or B), or any combination two or more of the above items (A and B), unless otherwise indicated or explicitly prescribed by the context. The terms “comprising,” “having,” “including,” and “comprising” should be construed as open terms (ie meaning “including, without limitation,”) unless otherwise indicated. Indication of ranges of values serves only as a short way of indicating separately for each of the values included in the specified range, unless otherwise indicated, and each individual value is included in the present description, as if it were separately indicated in the present description. All of the described methods can be carried out in any suitable order, unless otherwise indicated or explicitly prescribed by the context. The use of any and each of the examples, or the language of the examples provided (for example, “such as”) is intended only to better illustrate the present invention and should not impose restrictions on the scope of the present invention, unless otherwise indicated in the claims. The language of description should not be construed as indicating any element not indicated in the claims as essential for the practical implementation of the present invention.

[0202] Preferred embodiments of the present invention are described herein, including the best mode of carrying out the present invention known to the inventors. Variants of these preferred embodiments may be understood by one of ordinary skill in the art upon reading the foregoing description. The inventors believe that those skilled in the art will accordingly be able to apply these options, and the inventors expect the present invention to be practiced differently than specifically described herein. Therefore, the present invention includes all modifications and equivalents of the subject matter of the present invention indicated in the attached claims, as permitted by applicable law. In addition, any combination of the above elements in all their possible variants is included in the scope of the present invention, unless otherwise indicated or explicitly prescribed by the context.

Claims (15)

1. A drying type suture sealant composition comprising:
(a) an astringent selected from polymers of acrylic acid, copolymers of acrylic acid, alkyds, polyurethanes, polyesters, epoxides and combinations of these compounds; and
(b) a plurality of hollow balls, said balls having an average isostatic crushing strength of at least about 100 psi (689 kPa), measured according to ASTM D3102-78. 2. The composition of the suture sealant according to claim 1, characterized in that the composition has a density of from about 2 f / gal. up to about 8 psi, and the composition has a shrink of about 2% or less, measured according to ASTM C474-05. 3. The suture sealant composition according to claim 1, characterized in that the composition essentially does not contain setting minerals, bulk filler, clays, starch, mica, calcium carbonate, expanded perlite, calcium-magnesium carbonate, limestone, calcium sulfate dihydrate, attapulgite clay, kaolin clay, talc, diatomaceous earth or a combination of these materials. 4. The suture sealant composition according to claim 1, characterized in that the binder has a glass transition temperature (Tg) of from about 32 ° F (0 ° C) to about 70 ° F (21 ° C). 5. The composition of the suture sealant according to claim 1, characterized in that the binder has a minimum film formation temperature (MTP) from about 32 ° F (0 ° C) to about 90 ° F (32 ° C). 6. The suture sealant composition according to claim 1, characterized in that the balls have an isostatic crushing strength of at least about 250 psi (1724 kPa). 7. The composition of the suture sealant according to claim 1, characterized in that the balls have a density of from about 0.0015 f / in ³ (about 0.04 g / cm ³ ) to about 0.04 f / in ³ (about 1.1 g / cm ³ ). 8. The suture sealant composition according to claim 1, characterized in that the balls contain calcareous borosilicate, polystyrene, ceramic material, recycled glass, foamed glass and light polyolefin granules, thermoplastic material, thermosetting material, or any combination of these materials. 9. The composition of the drying type suture sealant according to claim 1, characterized in that the binder is present in an amount of from about 3% to about 90% by weight of the wet composition,
and while the balls are present in an amount of from about 5% to about 25% by weight of the wet composition. 10. The drying type suture sealant composition according to claim 1, further comprising at least one of the following substances: a nonionic surfactant in an amount of from about 0.001% to about 5% by weight of the wet composition; a humectant in an amount of from about 0.001% to about 3% by weight of the wet composition; defoamer in an amount of from about 0.05% to about 5% by weight of the wet composition; a rheological modifier in an amount of from about 0.1% to about 5% by weight of the wet composition; and a biocide in an amount of from about 0.1% to about 1.5% by weight of the wet composition. 11. A wall structure comprising:
(a) two adjacent plates joined by a seam;
(b) a single layer of suture sealant composition according to claim 1 in the seam to provide a uniform aesthetically pleasing appearance; and
(c) dimensionally stable, non-swellable, flat joint tape included in the seam. 12. The wall structure of claim 11, wherein the at least one plate has a beveled edge adjacent to the seam, and the maximum depth of the beveled edge is about 0.125 inches (about 0.318 cm) or less. 13. The wall structure according to claim 11, further comprising a reinforcing patch located over the seam, said patch comprising (i) a liner containing paper having a dimensional stability of less than about 0.4% expansion in the processing direction and less than about 2, 5% lateral expansion after immersion in water for 30 minutes when measured according to ASTM C474-05, Section 12, and (ii) a reinforcing substrate containing paper, plastic, natural or synthetic fiber, carbon fiber, polyester, polycarbonate, stack a fiber, non-woven natural or synthetic materials, woven natural or synthetic materials, spun polyolefin or metal, said substrate having a thickness of from about 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0.2 cm). 14. The wall structure of claim 11, further comprising at least one carcass element and glue, said glue at least partially securing at least one plate to the carcass element. 15. A method of processing a wall structure containing two adjacent plates connected by a seam, including:
(a) applying a tape to seal the seams and one layer of the composition of the suture sealant according to claim 1 on the seam; and
(b) drying the composition.

Images