Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/30—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by mixing gases into liquid compositions or plastisols, e.g. frothing with air
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/66—Sealings
  • E04B1/68—Sealings of joints, e.g. expansion joints
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
  • C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
  • C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor

Definitions

• Latex foams have been used as sealants and caulks around windows in houses under construction. Typically, such foams are dispensed from cans and expand upon application. Also, foams are designed to fit in tight slots and not over joints with open space on one side. As such, these foams tend not to adhere well to wood or gypsum sheathing, leaving joints unevenly covered. When such foams dry, however, they are difficult to compress such that they are typically not used to seal joints between
• This invention is a method of making a weather-resistive barrier on a building under construction that employs adjacent sheets of wood, cement or gypsum exterior sheathing on a structural frame with gaps between the sheets, comprising:
• a foamed aqueous emulsion polymer composition to the gaps wherein the composition comprises an aqueous emulsion polymer with a Tg less than 25° C., a surfactant, water and a blowing agent wherein a wet, freshly applied 12 mm thick and 50 mm wide bead of the foamed composition has the ability when dried to be compressed to a thickness of not more than 3 mm under a stress of no more than 0.035 MPa; and
• the method of this invention further comprises installing a decorative cladding over the coated sheathing.
• the foamed composition (a) has the ability when dried to be compressed to a thickness of not more than 3 mm under a stress of no more than 0.0035 MPa. In one embodiment, the foamed composition (a) has the ability to self-compress to not more than 3 mm under no externally applied stress.
• At least one of the compositions (a) or (b) comprises a polyfunctional amine or a polyethyleneimine to facilitate skinning of the compositions so as to resist rain while the composition(s) is drying, or to allow further coatings to be more quickly applied over those compositions.
• the foam component (a) or the coating component (b) or both it may be desired to cause faster setting or skinning than would otherwise occur by drying. This may be advantageous in preventing a recently applied but incompletely dried weather resistive barrier from being washed off by a sudden rainstorm. This also may make for faster installation with coating (b) applied minutes after foam (a) installation. Accelerated setting or skinning can be achieved by including in the formulation a polyfunctional amine as disclosed in U.S. Pat. No. 5,804,627 (Rohm and Haas) or a polyethyleneimine as disclosed U.S. Pat. No. 6,376,574 (Dow).
• the coating composition (b) should be selected so as to allow for an appropriate water vapor transmission for the building.
• HVAC heating, ventilation and air conditioning
• the coating component (b) should be chosen to give a finished weather resistive barrier with an appropriate water vapor transmission rate to reduce any moisture condensation in the walls of the building.
• This vapor transmission rate is most often measured according to ASTM E-96 and expressed in units of perms, where higher perms correlate with a greater rate of water vapor transmission.
• OSB a common sheathing material, has approx 3-6 perms.
• a weather resistive barrier (b) with >10 perms may be desired, so that any moisture which reaches the OSB is not unduly inhibited from diffusing through the barrier (b) to the exterior.
• coating formulation can make coatings with a desired perm value, measuring candidate coating compositions (b) according to ASTM E-96.
• composition for the coating component (b) include:.
• RhoplexTM EC-2540 (a flexible, acrylic polymer emulsion) without any further additives.
• RhoplexTM EC-2540/10 parts RopaqueTM Ultra E a non film forming polymer which provides coating opacity
• Sto Gold Coat (a yellow coating based on styrene-acrylic copolymer, with 5.7 Perms) from Sto Corp of Atlanta, Ga.
• Henry Airbloc 33 (a black coating based on acrylic copolymer, with 11.6 Perms) from Henry Inc. of Huntington Park, Calif.
• Henry Airbloc 06WB (a black coating based on asphalt emulsion, with 0.02 Perms) from Henry Inc. of Huntington Park, Calif.
• a suitable composition (b) is given in Example 16 below.
• Coating composition (b) can be applied by spray equipment, brush or roller.
• Aqueous polymers and copolymers suitable for both the foam aqueous component (a) and for the coating component (b) used in this invention can be acrylic class or vinyl acetate-acrylic class of polymers, as shown in the examples.
• Other classes of polymers are also suitable, such as styrene-acrylics (e.g. RhoplexTM 2019R from Rohm and Haas or Acronal S-400 from BASF); ethylene-vinyl acetates, styrene-butadienes, and polyurethane dispersions, examples of which are described in U.S. Pat. No. 7,179,845 (Fomo Products Inc.).
• Useful acrylic emulsion polymers include RhoplexTM EC-2540, RhoplexTM M EC-1791 QS, RhoplexTM MC-1834, RhoplexTM AC-630.
• RovaceTM 9100 is an acrylic-vinyl acetate copolymer. The Rhoplex and Rovance polymers are available from Rohm and Haas Co. of Philadelphia, Pa.
• the foam component (a) contains a surfactant.
• surfactants and combinations thereof can be suitable for generation and stabilization of aqueous foams (a) used in this invention.
• nonionic surfactants include those based on ethoxylated octylphenol (TRITONTM X series), ethoxylated nonylphenol (TERGITOLTM NP series), ethoxylated secondary alkyl alcohols (TERGITOLTM TMN and 15-S series), all available from Dow Chemical, and linear alcohol ethoxylates in the Brij series from ICI Americas.
• Suitable anionic surfactants include anionic sulfates, sulfonates, phosphates or phosphonates such as sodium lauryl sulfate (e.g. Stanfax-234 from Para-Chem), sodium salts of sulfated fatty alcohol ethoxylates (e.g. Disponil FES-32 from Cognis Corp.), sodium dodecylbenzene sulfonate (e.g. Rhodacal DS-4 from Rhodia Corp.), sodium dioctyl sulfosuccinate (e.g. Aerosol OT-70 from Cytec Industries), ammonium salt of alkyl ethoxylate phosphate (e.g.
• Rhodacal RS-610 from Rhodia Corp.
• anionic carboxylate salts such as ammonium stearate and potassium oleate (e.g. Stanfax-320 and Stanfax-1 respectively, from Para-Chem).
• Preferred anionic surfactants are salts of stearic acid, particularly ammonium and potassium salts.
• Suitable cationic surfactants include those disclosed in U.S. Pat. No. 7,179,845 (Fomo Products Inc.) and in U.S. Pat. No. 5,696,174 (Allied Foam Tech Corp)
• Suitable blowing agents to make the foam component (a) include air, carbon dioxide, nitrogen, low boiling hydrocarbons (e.g., propane, butane, isobutane) and low boiling halocarbons, and lower alkyl ethers (e.g., dimethyl ether). Air or carbon dioxide are preferred.
• low boiling hydrocarbons e.g., propane, butane, isobutane
• low boiling halocarbons e.g., dimethyl ether
• Optional ingredients in both the (a) and (b) compositions include biocides, rheology modifiers, extenders (fillers), opacifying pigments (mineral and organic (e.g. opaque polymer)), fly ash, dispersants, defoamers, UV stabilizers, colorants, fire retardants, pH adjusters or buffers, coalescents, cosolvents, glass fibers, carbon fibers, microbeads and anti-freeze agents.
• foam generator/applicator equipment include static mixers, as disclosed in U.S. Pat. No. 5,492,655 (Schuller International Inc.), U.S. Pat. No. 4,986,667 (3M), and U.S. Pat. No. 6,422,734 (National Gypsum LLC).
• Still other foam generators include venturi or air eductors to draw and mix air into a fluid stream, such as disclosed in U.S. Pat. Nos. 6,010,083 (BetzDearborn Inc.), U.S. Pat. Nos. 6,042,089, and 6,561,438 (Fountainhead Group).
• the aqueous foam component (a) can also be dispensed from a pressurized aerosol container, as disclosed in U.S. Pat. No. 7,029,609 (Rathor) and references contained therein.
• Foamaster NXZ defoamer
• Snowhite 12 calcium carbonate
• Colortrend “F” 888-1045 colorant
• Degussa Corp is available from Degussa Corp.
• TamolTM 850 dispenserant
• AcrysolTM TT-615 rheology modifier
• Imsil A-150 is ground silica from Unimin Specialty Minerals Inc. of Elco, Ill.
• DAP is DAP Tex Plus available from DAP Inc. of Baltimore, Md. It is a water-borne foam delivered from an aerosol can, propelled with a mixture of propane, butane and methyl ether.
• a stiff aluminum plate 75 mm long ⁇ 25 mm wide ⁇ 3.3 mm thick was laid across the dried foam band, to span the width of the band completely and have a contact area between the plate and foam of 25 mm ⁇ 50mm (1 ⁇ 2 inches). Weights were placed onto the plate to give a total weight of 225 g, (approx 0.5 lb) creating a pressure of about 0.0035 MPa, and the height of the foam under the plate was measured after 1 minute, and entered into Table 1 as “H225 g.” If this value was >2 mm, weight was increased to 2.2 kg (approx-5 lbs) creating a pressure of about 0.035 MPa, the height was measured after 1 minute and entered in Table 1 as “H2:2 kg.”
• Foams were generated from other latexes in the same manner as examples 1-8. Their characteristics are reported in Table 2.
• a foam composition (a) from the same basic coating composition that is used for coating (b).
• the advantage of this approach is that one can simply add suitable materials to composition (b) to create a foam (a). In this fashion, one can then make a coating (b) that can be also be used to make a foam (a) with the addition of a few additional ingredients.
• the above recipe was made on a 5000 g scale. During the initial weigh out, materials were added in order one at a time to a grind pot. Following each addition, the contents of the pot were briefly agitated by swirling. After the addition of RhoplexTM EC-2540 the grind pot was transferred from the bench top and placed on the CowlesTM high speed disperser to mix and grind ingredients. Snowhite 12 was slowly added to ensure good dispersion. Agitator speed was initially set to 1000 rpm and was increased with addition of the Snowhite 12 to approximately 1300 rpm. Foamaster NXZ was added immediately following the Snowhite 12 addition, and the grind was held for 5 minutes for full incorporation. Following the addition of the AcrySolTM TT-615, the grind was held for 20 minutes. During this time the agitator speed was increased to between 2000-3000 rpm depending on conditions. Grind was filtered with 100 mesh and de-aired using a vacuum canister and agitator.
• Sheets of foam were prepared as in example 15b. After the foam dried for 2 days, the coating of example 16 was applied by brush in 2 coats over the foam with 2 hours of drying between coats then dried overnight, to a final coating thickness of approximately 15 dry mils (0.38 mm). After drying overnight, the coated foam was subjected to a falling dart impact tester, of 908 g (2 lb) weight and 12 mm (0.5 inch) spherical tip. The dart was dropped on a fresh area of coated foam resting on a hard flat board from progressively higher heights, until the coating was visibly torn. The coated foam of Example 6 passed to 430 mm (17 inches) and failed 480 mm (19 inches). Comparative example DAP failed at the lowest height, 12 mm (0.5 inches).
• OSB oriented strand board
• a band of foam of example 6 was applied 50 mm wide and 12 mm thick when wet over and across the gap and dried overnight to form a foam bridge approx 3 mm thick.
• the coating of example 16 was then applied across the joint and over the OSB rectangles by brush in 2 coats with 2 hours of drying between coats then dried overnight, to a final coating thickness of approximately 15 dry mils (0.38 mm).
• the clamps were removed to free the rectangles from the supporting board to provide a test joint spanned by foam and entirely covered by the coating. Due to the foam in the joint, the center of the coated joint was only approximately 2 mm higher than the plane of the coated OSB outside the area which had received the band of foam. However, the foam could be flattened even further with gentle finger pressure. Multiple samples of these joints were used in the following water tightness test.
• the water was emptied and the assembly was dried 24 hours. It was then filled to a depth of 55 cm to provide a head pressure of water over the joint. At 5 hours, no leaks were detected.
• a mixture of 95 g of RhoplexTM EC-2540, 4 g of Stanfax-320 and 1 g of Stanfax-234 was placed into a an aluminum can (200 mL are available from McKernan Packaging Clearinghouse of Reno, Nev.) which was closed with a bottle closure (Body Orifice #062, Stem Orifice #018 and a Spout # S20L7, all available from Seaquist Perfect Dispensing of Cary, Ill.). The can was then charged with 2.0 g of propane and 4.0 g of n-butane. The can was shaken for 30 sec, inverted and the trigger depressed, to dispense a foam of similar properties as in example #1 above.
• a flexible hose was affixed to the can spout before dispensing to allow the stream of foam to be directed into and over a joint between OSB boards.
• a flattened funnel (opening 42 mm wide ⁇ 4 mm thick) was affixed to the end of the flexible hose, allowing a band of foam to be applied over the gap in a rapid single pass.
• Aerosol cans as in Example 20 were filled with the following recipes, then were kept on a shelf for 3 months to monitor their storage stability.
• foams were discharged and troweled into a band 50 mm wide and 12 mm thick on a flat board and the thickness of the band was measured periodically for 24 hours, after which no further thickness changes were seen. All foams expanded in size for approximately 2 hours after the time of application. Overnight, the foams which are suitable as a component of the invention reduced to 25% of their as-applied thickness or less. The comparative DAP example continued to expand beyond the 2 hour mark, and its ultimate thickness was about double its as-applied thickness.

Landscapes

• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Architecture (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Health & Medical Sciences (AREA)
• Materials Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Paints Or Removers (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

Priority Applications (1)

Applications Claiming Priority (2)

Publications (1)

Family

ID=40350105

Family Applications (2)

Family Applications After (1)

Country Status (7)

Cited By (4)

Families Citing this family (6)

Citations (25)

Family Cites Families (22)

• 2008
  • 2008-10-06 JP JP2008259784A patent/JP5292046B2/ja active Active
  • 2008-10-10 AU AU2008229877A patent/AU2008229877B2/en active Active
  • 2008-10-14 US US12/287,863 patent/US20090107080A1/en not_active Abandoned
  • 2008-10-15 EP EP08166703A patent/EP2053081A3/en not_active Withdrawn
  • 2008-10-17 CA CA002641242A patent/CA2641242A1/en not_active Abandoned
  • 2008-10-23 CA CA2641792A patent/CA2641792C/en active Active
  • 2008-10-23 US US12/288,829 patent/US8151538B2/en active Active
  • 2008-10-24 KR KR1020080104613A patent/KR101061780B1/ko active IP Right Grant
  • 2008-10-24 CN CN2008101750584A patent/CN101418594B/zh active Active
  • 2008-10-27 CN CN2008101747492A patent/CN101446114B/zh active Active

Patent Citations (30)

Also Published As

Similar Documents

Legal Events