WO2005056489A1 - Compositions de coulis a base de polymeres - Google Patents

Compositions de coulis a base de polymeres Download PDF

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Publication number
WO2005056489A1
WO2005056489A1 PCT/US2004/040325 US2004040325W WO2005056489A1 WO 2005056489 A1 WO2005056489 A1 WO 2005056489A1 US 2004040325 W US2004040325 W US 2004040325W WO 2005056489 A1 WO2005056489 A1 WO 2005056489A1
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WO
WIPO (PCT)
Prior art keywords
grout
grout composition
compositions
present
color
Prior art date
Application number
PCT/US2004/040325
Other languages
English (en)
Inventor
Gregory W. Schad
Vanda I. Wolinsky
Bronwyn T. Miller
Original Assignee
Speciality Construction Brands, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/729,630 external-priority patent/US7303068B2/en
Priority claimed from US10/729,116 external-priority patent/US7005462B2/en
Application filed by Speciality Construction Brands, Inc. filed Critical Speciality Construction Brands, Inc.
Priority to AU2004297194A priority Critical patent/AU2004297194B2/en
Priority to MXPA06006113A priority patent/MXPA06006113A/es
Priority to CA2549165A priority patent/CA2549165C/fr
Publication of WO2005056489A1 publication Critical patent/WO2005056489A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C08L101/10—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing hydrolysable silane groups
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/30—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Other silicon-containing organic compounds; Boron-organic compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0641—Mechanical separation of ingredients, e.g. accelerator in breakable microcapsules
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/34—Filling pastes

Definitions

  • the present invention relates to novel shrink and/or crack resistant one-part polymer grout compositions that are tintable at a point of sale. More particularly, and due at least in part to the inclusion of one or more fiber fillers, rheology modifying agents, dispersants and/or surfactants, the present grout compositions may be provided to a retailer in any number of tintable base formulations, that may then be tinted to a virtually infinite number of colors via standard paint tinting equipment. This combination of properties renders the present grout compositions suitable for use in a wider variety of applications than conventional one-part polymer grouts.
  • cement grout there are at least 4 different types of grout to choose from in order to fill the joints between placed tiles, i.e., cement grout, polymer modified cement grout, two part polymer grout, and one part polymer grout. Although each of these may be suitable or desirable depending upon e.g., the particular application and the installer's preference, one part polymer grout is the only one that offers the convenience of being available in a pre-mixed state.
  • one part polymer grout hardens, and perhaps cross links to some extent, merely upon drying, the other grouts cure or harden upon the addition of water, or in the instance of two part polymer grout, upon the combination of the two parts. As such, these grouts must be mixed at the time of use and once mixed must be used quickly prior to their hardening to such an extent as to become unusable.
  • one-part polymer grouts thus provide a significant convenience to tile installers, those currently in the marketplace are not optimal for all applications.
  • currently commercially available one-part polymer grouts are only available in a limited amount of premixed colors (typically white, black and shades of brown and gray), thus limiting their use to those projects where these colors will coordinate.
  • one-part polymer grouts are also not sufficiently strong, shrinkage and/or crack resistant in order to be suitable for use in many environments.
  • conventional one-part polymer grouts can be susceptible to shrinkage or cracking, especially when utilized with tile that absorbs substantial amounts of water itself, such as clay-bodied tile.
  • the convenience of use of one-part polymer grouts could thus be enhanced if such pre-mixed grouts were available in a wider variety of colors.
  • One-part polymer grouts could further be improved if they were suitable for use in a wider variety of applications than currently available one-part polymer grouts.
  • the present invention relates to novel one-part polymer grout compositions that may be tintable to any of a wide spectrum of colors with conventional paint tinting systems, comprising e.g., color decks, tint agents, tinting equipment and shakers, common in many hardware and home improvement stores.
  • conventional paint tinting systems comprising e.g., color decks, tint agents, tinting equipment and shakers, common in many hardware and home improvement stores.
  • the present grout compositions may also be substantially shrinkage and/or crack resistant, so as to be suitable for use in joint spaces up to 1/4" wide.
  • the grout compositions can also be water and/or stain resistant, further enhancing the convenience of the present grout compositions.
  • the present invention provides a one-part polymer grout composition tintable upon request to provide a stable, uniformly tinted, grout composition.
  • the present grout compositions may be tinted using any of a number of commercially available universal colorants or tints uniformly, i.e., to a color dispersion of less than at least about 0.5.
  • the tint is stable within the grout composition when subjected to accelerated aging conditions, i.e. oven storage at 50°C for a period of at least about 14 days, or about 28 days, or even about 6 weeks.
  • grout compositions can be so tinted, conveniently and advantageously using commonplace equipment for tinting and mixing paint and stain to custom colors, via the inclusion therein of at least two fiber fillers. While not wishing to be bound by any theory, it is believed that the fiber fillers can act as shear thinning agents when the grout composition is agitated to assist in the dispersion of the tint there through. It is further believed that the fiber fillers can also act as agitation facilitators, by enhancing the agitation of the grout via the movement imparted to the fibers upon shaking.
  • the ability to provide one-part polymer grout compositions on demand according to any desired color represents a significant advance inasmuch not only due to the previously unrealized convenience that this represents, but also because a much wider variety of colors can be provided than have been commercially provided in the past. That is, and although colored one-part polymer grout compositions have been commercially available for some time, the available colors are extremely limited, often being limited to brown, gray or black.
  • the present inventive grouts can be custom colored to any of a virtually infinite number of colors, according to the consumer's needs or preference.
  • the present invention also provides a method of providing a tinted one-part polymer grout composition upon request.
  • the method comprises providing a one-part polymer grout, adding one or more universal colorants to the grout composition capable of providing the tinted grout requested, and agitating the grout composition to provide the requested tinted grout composition.
  • the universal colorants to be used to provide the requested color can be determined via visual color matching, computerized color matching, or in the instance wherein the requested color is commercially available from a fandeck of color formulations, may simply be determined by reference to the formula associated with the color. Due to the convenience provided by the same, the provision of a fandeck of colors is contemplated. That is, and although many talented paint matching and mixing professionals exist who are capable of providing visual color matching with minimal trial and error, these professionals may not be present in every desired retail outlet for present grout compositions.
  • the present invention also contemplates a kit comprising a tintable one-part grout composition as well as instructions for adding one or more universal colorants to the tintable grout composition to provide a tinted grout composition.
  • the instructions e.g., may be in the form of at least one fandeck of color formulations based upon universal colorants.
  • the universal colorants upon which the at least one fandeck is based may be provided.
  • fandecks based upon a plurality of colorants may be provided, so that no matter what colorant system may be available in any given outlet, a consumer may take advantage of the convenience afforded by the kit embodying features of the present invention.
  • grout is meant to indicate a composition, whether sanded or unsanded, suitable for filling joint spaces between tiles in vertical or horizontal applications, and thus, generally speaking, having a viscosity of at least about 100,000 cps or about 600,000 cps, or even 1,000,000 cps.
  • grout compositions are also desirably readily removable from a tile surface once applied and dried. For some grout compositions this may indicate that a minimum film formation temperature of at least about 20°F, or a T g greater than about 30°F may be required.
  • one-part polymer composition is meant to indicate a grout composition that hardens, or 'cures', via the evaporation of water, rather than via a chemical reaction between two parts, whether or not one of the two parts is water, as is the case with, e.g., cement.
  • sanded grout and “unsanded grout” are meant to indicate grout compositions that include an amount of sand as a filler, or don't include such an amount, respectively.
  • twintable is meant to indicate the capability of being stably and uniformly tinted using universal colorants, tints or pigments.
  • a grout composition is deemed to be uniformly tinted if it attains a color dispersion measurement value of 1.5 or less, 1.0 or less, or even less than 0.5 and is considered stable if the colorant remains substantially dispersed in the grout composition for a period of at least about 14 days, or at least 28 days, or even at least about 6 weeks when the grout composition is subjected to oven accelerated aging at 50° C.
  • the phrases “shrink resistant” or “crack resistant” are meant to indicate that no cracking or sinking of the grout composition, visible upon inspection with the naked eye, is seen once a 12" x 16" tile installation, with 3/16" minimum grout joints for sanded grout, and an 8" x 8" tile installation, with 1/16" minimum grout joints for unsanded grout, has been installed and allowed to dry.
  • the phrase “water-resistant” is meant to indicate a grout composition that meets or exceeds the requirement for standard cement grout provided in American National Standard Specifications ANSI A 118.6 and 118.7, as measured by the method also provided therein.
  • a water-resistant grout composition may advantageously maintain a Shore A hardness value of at least about 50, or 60, or even 75 after being submerged in water for a period of seven days.
  • stain resistant is meant to indicate an averaged score of from about 0 to about 2 as measured according to Ceramic Tile Institute Stain Test CTE-T-72.
  • silane group SiR 3
  • R can be any alkyl or cycloalkyl group and desirable may be e.g. a methyl, ethyl, propyl, or butyl group has been chemically linked to at least one monomeric unit of a polymer.
  • the phrase "weight percent”, and the abbreviation thereof “wt” are meant to indicate weight percent as based upon the total weight of the grout composition.
  • the present invention relates to novel one-part grout compositions that are tintable upon request to any desired color using universal colorants as potentially may be facilitated by the ability to utilize tinting and mixing equipment commonly used to tint paint or stain.
  • the present grout compositions can be any desired color as may be selected by a consumer from a virtually infinite array of choices.
  • the grout compositions may also advantageously be substantially shrinkage and/or crack resistant further enhancing their applicability to any desired tile application.
  • the present grout compositions are expected to be useable with tiles made from any material, with substantially no shrinking or cracking.
  • the grout compositions may also be surprisingly strong, as well as being substantially water and/or stain resistant.
  • the present one-part polymer grout compositions can meet or exceed the strength, water and stain resistance requirements, and further can even achieve a residential installation rating, according to the industry standards for cement grout.
  • the present grout compositions may be utilized in applications wherein the use of conventional one-part polymer grouts had previously been contraindicated.
  • the present invention thus provides a one-part polymer grout composition that is tintable upon request to provide any desired color.
  • the present grout compositions can be tinted with such commercially available colorants, and if desired, equipment, to grout compositions that are substantially uniformly tinted not only to the naked eye, but also when measured using a Spectraflash® 600 Plus (Datacolor International) spectrophotometer.
  • the present grout compositions are capable of being tinted to a color dispersion of less than at least about 1.5, or even less than about 1.0, or even less than about 0.5.
  • the present grout compositions are stable when so tinted, i.e., the tint pigment or agent remains substantially dispersed within the grout composition, with no visible separation thereof for at least about 14 days, or at least about 28 days, or even for at least about six weeks, when subjected to heat accelerated shelf stability studies. Significantly, six weeks of accelerated aging is considered to be representative of at least a one-year shelf life at normal, ambient storage conditions. It has now been discovered that grout compositions may be rendered so tintable via the inclusion of one or more fiber fillers, either alone, or in combination with one or more rheology modifiers, surfactants and/or dispersants.
  • fiber fillers can sufficiently assist in the dispersion of tinting agents throughout the present grout compositions to provide the desired uniformity and stability by acting as rheology modifiers, i.e., by causing a reduction in the viscosity of the grout compositions when shaken, or otherwise agitated, in a paint mixer, and that this reduction in viscosity may facilitate the uniform dispersion of tint throughout the grout composition.
  • the fiber fillers may also act as mixing facilitators, i.e., by enhancing the shaking or agitation action within the grout composition via the motion imparted to the fibers via the shaking or agitation of the grout composition.
  • the fiber filler(s) can further provide the grout composition, once applied and dried, with shrinkage and/or crack resistance. That is, and inasmuch as one-part polymer compositions harden simply by the evaporation of water, or other solvents, they can be prone to shrinkage or cracking.
  • the inclusion of fiber fillers can act to provide an interlocking network that can, in turn, increase the cohesiveness of the grout compositions upon drying so that substantial shrinking or cracking is not seen. As a result, the present grout compositions can be even more suitable for use in larger joint spaces.
  • Fiber fillers comprising any material are believed to be capable of providing at least some rheology modification and/or mixing facilitation, and many types of fiber fillers are known and commercially available.
  • Mineral fillers for example, are commercially available under the trade designations Nyad® G or Wollastocoat® (Nyco, Calgary, Alberta, Canada) or MS605 Roxul 1000 (Lapinus Fibres BV, Roermond, Netherlands), while one example of a commercially available cellulose fiber filler is that having the trade name Arbocel® (all grades) from J.
  • any of these, or any other commercially available fiber filler comprising any material may be utilized alone or in combination in the present grout compositions.
  • the amount of any such fiber filler(s) utilized will depend at least in part on the particular fiber filler chosen. Of course, the total amount of fiber filler utilized will desirably be enough to at least minimally assist in tint dispersion throughout the grout compositions, but yet not so much as to detrimentally impact any other desirable properties thereof.
  • amounts of mineral fibers when used alone, ranging from about 0.1 to about 20 wt%, or from about 1 wt% to about 10 wt%, or even from about 2 wt% to about 6wt can provide the desired rheology modification or other assistance in tint dispersion.
  • Cellulose fibers in amounts ranging from about 0.05 wt% to about 2 wt%, or 0.1 wt% to about 1 wt%, or from about 0.2 wt to about 0.9 wt% are believed to be capable of providing minimal improvement in tint dispersion in the present grout compositions.
  • Combinations of fillers comprising a variety of materials may be used, and if the same is desired, each type of fiber may be included in the combination in an amount according to the ranges provided herein.
  • the tintability of the grout compositions may be further enhanced via the inclusion therein of one or more rheology modifiers, surfactants and/or dispersants.
  • rheology modifiers are known and commercially available and any of these may be used in the present grout compositions. For example, "Rheology Modifiers Handbook: Practical Use and Application", David R. Braun and Meyer R.
  • rheology modifiers may be comprised of acrylic polymers; cross-linked acrylic polymers; alginates; associative thickeners; carrageenan; cellulose derivatives, including, but not limited to, microcrystalline cellulose, carboxymethylcellulose sodium, hydroxyethylcellulose, hydroxypropylcellulose, and methylcellulose; guar and guar derivatives; locust bean gum; organoclays and other clays; polyethylene oxide; polyethylene; polyvinyl pyrrolidone silica; xanthan gum; or combinations of these.
  • rheology modifiers that may be suitable for use in the present grout compositions include any or all of the grades available under the trade names Carbopol® (Noveon Inc., Cleveland, OH); Cab-O-Sil® (all grades, Cabot Corp., Tuscola, IL); Aerosil® (all grades, Degussa, Piscataway, NJ); Bermocoll® (all FQ grades, Akzo Nobel Stenungsund, Sweden); Cellosize® (all Q grades, The Dow Chemical Co., Midland, MI); Tylose® (all grades, Clariant Corp., Charolette, NC); Acrysol® (all grades, Rohm & Haas, Philadelphia, PA) and Attagel® (all grades Engelhard, Iselin, NJ).
  • Carbopol® Noveon Inc., Cleveland, OH
  • Cab-O-Sil® all grades, Cabot Corp., Tuscola, IL
  • Aerosil® all grades, Degussa, Piscataway, NJ
  • Amounts of the rheology modifiers will depend not only on the particular rheology modifier used, but also on the desired effect of the same. That is, while rheology modifiers may surprisingly result in the present grout compositions being tintable at a point of sale, this may not be desired or required in all instances.
  • the amount of rheology modifiers included will desirably be capable of providing a reduction in viscosity of at least about 35%, or about 40%, or even at least about 50%, so that the tinting agent may be uniformly dispersed within the grout composition.
  • polymeric and cellulosic rheology modifiers may generally be included in the present grout compositions in amounts ranging from about 0.05 to about 2 weight percent, in some embodiments from about 0.1 to about 1.5 wt% and in yet other embodiments, from about 0.2 wt% to about 1 wt%, based upon the total weight of the grout composition, while fumed silica and clay rheology modifiers may suitable be included in the grout compositions in amounts ranging from about 0.05 wt% to about 5 wt%, in some embodiments from about 0.1 wt% to about 4 wt%, and in yet other embodiments from about 0.5 wt% to about 3 wt%.
  • One or more surfactants and/or dispersants may also desirably be included in the present grout compositions as may be desired to assist not only in the uniform dispersion of the tint throughout the grout composition upon shaking, but also to assist in the stability of the tint within the grout composition once so uniformly dispersed.
  • Many dispersants and surfactants suitable for use in conventional compositions are known and any of these may be used in the present tintable grout compositions.
  • a few examples of commercially available dispersants include those provided under the trade designations Colloid 211 (Rhodia USA, Cranbury, NJ), Sokalan® CP13S (BASF Inc.
  • surfactants include, but are not limited to, those provided under the trade designations T-Det® N407 and Triton® XI 00 (Harcros Chemicals, Inc., Kansas City, Kansas and Rohm and Haas, respectively) As is understood by those of ordinary skill in the art, the amount of surfactant and/or dispersant utilized will depend upon the particular surfactant and/or dispersant selected.
  • the amounts utilized will at least minimally assist in the uniform dispersion of a tint within the grout composition, as well as the stability of the tint within the grout composition once so dispersed, but not so much as to substantially detrimentally impact other desirable properties of the grout compositions.
  • useful amounts of dispersants are expected to range from about 0.1 wt% to about 3 wt%, or from about 0.2 wt% to about 2 wt%, or even from about 0.5 wt% to about 1.5 wt%.
  • useful amounts of surfactants are expected to range from about 0.2 wt% to about 2 wt%, or from about 0.4 wt% to about 1.5 wt% or even from about 0.5 wt% to about 1 wt%. Due to the ability to tint the present grout compositions using common, commercially available paint tint agents and paint tinting and mixing equipment, and even further in light of the enhanced shrinkage and/or crack resistance exhibited by the same, the present one-part polymer grout compositions dramatically increase the currently limited applicability of one- part polymer grout compositions while yet maintaining the convenience provided by the one- part, no mixing required, system. The present invention yet contemplates and provides embodiments wherein certain properties of the grout compositions may be even further enhanced.
  • the present grout compositions can be provided to be surprisingly strong, as well as being substantially water and/or stain resistant.
  • the present grout compositions may be utilized in applications wherein the use of conventional one-part polymer grouts had previously been contraindicated.
  • Such advantageous properties may surprisingly be provided to the present grout compositions via inclusion therein of a silanated polymer, as described in commonly assigned co-pending patent application no. 10/729,116, filed on December 5, 2003, incorporated by reference herein in its entirety and for all purposes. Any silanated polymer, or dispersion or combination comprising the same, is believed to be capable of providing the present grout compositions with the surprising strength, water and stain resistance described herein.
  • acrylics and acrylic dispersions are acrylics and acrylic dispersions, since acrylic latexes/dispersions can tend to be stronger and more water resistant than other types of polymers. Additionally, many silanated acrylic latexes are readily commercially available, such as those commercially available under the trade designations Rhoximat® DS931
  • silanated polymers e.g. silanated acrylic latexes
  • silanated polymers are desirably included in the present grout compositions in total amounts ranging from about 8 wt% to about 40 wt%, or from about 10 wt% to about 30 wt%, and in certain embodiments, from about 10 wt% to about 20 wt%.
  • the present grout compositions may further comprise an amount of an acrylic dispersion, such as an acrylic/poly urethane dispersion.
  • an acrylic dispersion such as an acrylic/poly urethane dispersion.
  • the inclusion of such a dispersion can further enhance the water and/or stain resistance of the grout compositions as may be desirable in extremely wet applications.
  • it will be stabilized hybrid dispersion with enhanced interaction between the urethane and acrylic moieties, rather than a simple blend.
  • the dispersions are suitably utilized in amounts ranging from about 1 wt% to about 15 wt%, or from about 2 wt% to about 10 wt%, or even from about 3 wt% to about 5 wt%.
  • the grout compositions may exhibit surprising strength, e.g., the grout composition may be capable of meeting, or even exceeding the standards for flexural and tensile strength provided by the American National Standard Specifications for standard cement grouts, as well as achieving a residential installation rating under ASTM C627-76.
  • These embodiments of the present grout compositions are yet also surprisingly water and stain resistant, capable of meeting or even exceeding these standards for cement grouts provided by the American National Standard Specifications.
  • the stain resistance of the present grout compositions may also be further enhanced.
  • the present grout compositions may further comprise effective amounts of anti-microbial and/or stain resistance additives. The commercial market is replete with such agents, and any of these may be used to further optimize the stain resistance of the present grout compositions.
  • Zinc oxide is one example of a generic antimicrobial agent available from any of a number of sources, while other examples of antimicrobial agents include barium metaborate (Revelli, Chemicals, Inc., Greenwich, CT), Kathon® LX (Rohm & Haas, Philadelphia, PA) zinc omadine and sodium omadine (Arch Chemicals, Inc, Norwalk Connecticut) trichlosan (Ciba Specialty Chemicals, Basel Switzerland) or Troysan® 174 and Troysan® P20T (Troy Corporation, Florham Park, NJ). Suitable amounts of these will vary according to the particular antimicrobial agent chosen, but in each instance, suitable amounts are well known to those of ordinary skill in the art, and further may be available from the respective suppliers of each.
  • zinc oxide and barium metaborate may be included in the present grout compositions in amounts ranging from about 1 wt% to about 20 wt%, from about 3 wt% to about 15 wt% or even from about 5 wt% to about 10 wt%, while zinc and sodium omadine and trichlosan may be included, if desired, in amounts ranging from about 0.05 wt% to about 5 wt%, from about 0.1 wt% to about 4 wt% or from about 0.15 wt% to about 1 wt%.
  • Stin resistance additives include, but are not limited to,
  • Teflon powders such as Zonyl® MP1200 from DuPont; silicone/silane/siloxane emulsions including BS45 or BS1306 from Wacker Silicones, Adrian, MI; fluoropolymers emulsions like APG3312 from Advanced Polymer, Inc., Carlstadt, NJ; fluorinated silicone emulsions such as Visil FSE from Vitech International Inc., Janesville, WI; wax dispersions such as
  • Silicone/silane/siloxane emulsions, fluoropolymer emulsions and fluorinated silicone emulsions may be utilized, when desired, in amounts ranging from about 1 wt% to about 20 wt%, or from about 2 wt% to about 15 wt% or even from about 3 wt% to about 10 wt%.
  • the acrylic/ polyurethane dispersions can be provided in amounts ranging from about 1 wt% to about 15 wt%, from about 2 wt% to about 10 wt%, or from about 3 wt% to about 5 wt%.
  • suitable amounts of polyurethane dispersions can range from about 0.5 wt% to about 6 wt%, from 0.6 wt% to about 4 wt%, 0.8 wt% to about 1.5 wt%.
  • the present grout composition may further comprise any of the components otherwise found in conventional one-part polymer grout compositions.
  • the silanated polymer as may be provided to render the present grout compositions exceptionally strong, as well as water and/or stain resistant additives or antimicrobial agents as may optionally be provided to enhance stain resistance
  • the present grout compositions may include such conventional components as other fillers, solvents, humectants, plasticizers, preservatives, defoamers, adhesions promoters, pH modifiers, freeze-thaw stabilizers, anti-settling agents, etc.
  • each of these may advantageously be utilized in amounts typically utilized in conventional one-part polymer grout compositions, as may be readily determined by those of ordinary skill in the art and/or as may be provided by the supplier of each.
  • Other fillers in addition to the fiber fillers and optionally other rheology modifiers, may optionally be utilized in the present grout compositions to, e.g., impart desired application characteristics. Those of ordinary skill in the art are familiar with such fillers, commercial sources of the same, and amounts in which to use them to achieve whatever their desired effect.
  • Glass bubbles may be included to increase coverage abilities to the present grout compositions and are commercially available under the trade names Scotchlite® and Q-cell® (all grades of each, from 3M, Maplewood, MN and PQ Corporation, Valley Forge, PA, respectively). Ceramic microspheres may be included in the present grout composition for similar purposes and trade names of a few commercially available examples of the same include Fillite®500 (Trelleborg Fillite, Ltd., Norcross, GA), Zeospheres G600 (3M) and ExtendospheresTM SG, (PQ Corporation).
  • Silica sand is a common filler that may also be utilized to alter the application characteristics of the grout compositions, to assist in tint dispersion, and/or to improve the strength of the grout compositions, when desired. All fine or medium grades commercially available from Fairmont Minerals, Wedron, IL and U.S. Silica, Ottawa, IL are suitable for such purposes.
  • calcium carbonate may desirably be added as a fine filler in the grout compositions, and is particularly useful in those instances wherein the present water, stain and crack resistant grout compositions are desirably also tintable. Calcium carbonate is available generically from a number of chemical manufactures. As mentioned above, those of ordinary skill in the art are well aware, and/or well equipped to calculate, suitable amounts of such fillers.
  • glass bubbles and ceramic microspheres may be included in the present grout compositions, if desired, in amounts ranging from about 0.5 wt% to about 10 wt%, in certain embodiments from about 1 wt% to about 8 wt%, and in yet other embodiments from about 2 wt% to about 6 wt%.
  • Silica may be utilized, if desired, in the present grout compositions in amounts from about 20 wt% to about 60 wt%, in other embodiments, about 25 wt% to about 50 wt%, and in yet other embodiments, from about 30 wt% to about 45 wt%.
  • suitable amounts can range from about 5 wt% to about 50 wt%, in other embodiments from about 10 wt% to about 40 wt%, and in yet other embodiments from about 15 wt% to about 30 wt%.
  • Solvents may also be optionally included in the present grout compositions, as may be required or desired to provide improved application characteristics and/or to further improve crack and/or shrinkage resistance. Solvents useful in one-part polymer grout compositions are well-known, and include water, mineral spirits (generically available from many sources) and other organic solvents.
  • Suitable solvents include Texanol® and butyl cellosolv (Eastman Chemical Company, Kingsport, TN, and The Dow Chemical Company, respectively). Any solvents desired will be used in any amount required to achieve the desired effect as may be readily determined by those of ordinary skill in the art.
  • the exemplary solvents are expected to be suitable in amounts ranging from about 0.1 wt% to about 5 wt%, or from about 0.5 wt% to about 3 wt%, or even from about 1 wt% to about 2 wt %.
  • humectants and plasticizers are well known to those of ordinary skill in the art, and may be utilized in the present grout compositions as appropriate or desired.
  • humectants and plasticizers are known and are commercially available generically.
  • neopentyl glycol and urea are two well known humectants, widely commercially available from a variety of sources, while Benzoflex® 50 (Velsicol Chemical Company, Rosemount, IL) is but one example of a plasticizer suitable from use in the present grout compositions, if desired.
  • Suitable amounts, as well known to those or ordinary skill in the art, of these will of course depend upon the particular humectant or plasticizer chosen, but generally speaking, will range from about 0.1 wt% to about 3 wt%, or from about 0.2 wt% to about 2 wt%, or even from about 0.5 to about 1.5 wt%.
  • the present tintable grout compositions may be prepared according to any known method of preparing one-part polymer grout compositions systems, and the particular methodology employed is not critical. For example, the desired components may simply be placed in an appropriate container in appropriate amounts and mixed until a substantially uniform grout composition is achieved.
  • Particular non-limiting examples of sanded grout compositions embodying features of the present invention, as well as the methods of preparing the same, are provided below at Examples 1 and 2, while one exemplary embodiment of an unsanded grout composition in accordance with the present invention and method of its preparation is provided at Example 3.
  • the present grout compositions are tintable to any desired color, from a virtually infinite number of choices, to match any desired application site, in the same fashion as paint or stain.
  • the tintability of the present grout compositions to a much wider variety of colors represents a significant advantage to users of the same.
  • the grout compositions are so tintable upon request, i.e., the consumers of such grout compositions may tint the grout compositions themselves using commercially available tinting equipment, the operation of which is well known and understood by those of ordinary skill in the art, or by purchasing the present grout compositions from, or providing the grout composition to, any retail outlet having such tinting equipment.
  • the present invention thus also provides a method of providing a tinted grout composition upon request, comprising providing a one-part polymer grout composition, adding one or more universal colorants to the grout composition capable of providing the requested color, and agitating the grout composition to provide a tinted grout composition as requested.
  • Suppliers of such colorants may simply offer a collection of colorants, typically under a tradename, that may be combined in any combination to provide any desired color, i.e., as by computerized colormatching.
  • suppliers of such colorants may also offer formulations in combination with their colorants that may be used to achieve a particular collection of colors, often called "fandecks" of color.
  • the same supplier may further offer multiple lines of the same fandeck of color, in different compositions suitable for use to tint a variety of substrates, e.g., water-based or oil based paints or stains, or adapted to a particular customers needs.
  • Degussa Corporation (Parsippany, NJ) commercializes a collection of pigments and/or pigment compositions under the tradename Colortrend ® , as well as several fandecks of colors that may be prepared using these pigments, including, for example, Colortrend Nuance ® , Colortrend Ambience ® and Colortrend Folio ® . Further, Degussa also provides a line under the tradename Aquatrend ® that utilizes the Colortrend pigments, but is typically provided to industrial suppliers, so that paint matching for in-plant paint mixing and in-store paint mixing may be achieved. Any commercially available universal colorants suitable for use with paint or stain may be utilized to provide the present on-demand tinted grout compositions.
  • the colorants will be suitable for use in water-based systems, as may or may not be provided in a distinct formulation from those suitable for use in oil-based formulations by the supplier of the colorant.
  • the colorants may be provided as is, so as to be utilized at a mixing or retail facility by colormatching, whether done visually or by computer, or may be provided along with a fandeck of color formulations.
  • any of the colorants, suitable for use in a water based system, from any supplier are suitable for use to provide the on-demand tinted grout compositions according to the present invention.
  • colorants include, but are not limited to, those commercially available under the tradenames Tint-Ayd® UL (Whittaker, Clark & Daniels, South Plainfield, NJ) Aquatone® and Sunsperse® (SunChemical Corporation, Fort Lee, NJ) and Hostatint (Clariant Pigments and Additives, Coventry, RI) as well as any of those commercially available from Behr (Santa Ana, CA), BASF, Bayer (Leverkusen, Germany) and the like. If not provided in conjunction with a fandeck, the desired colorant line can have the requested color formulated therefrom via visual or computerized colormatching.
  • Visual colormatching can be done simply by adding one or more colorants to achieve the desired color, based upon the expertise and knowledge of the colormatcher. Additional colorants may be added in order to arrive at the requested color, at which time the tint formula employed to do so would be provided to the requester of the tinted grout composition so that further amounts could be purchased in the future, if desired. More commonly, color matching may be computerized, e.g., a sample of the color will be analyzed by a spectrometer. Software provided in connection with the spectrometer will then calculate a formulation of one or more colorants that will provide the requested color.
  • color matching systems are commercially available, and any of these may be utilized in order to provide the requested tinted grout composition. Examples of a few such colormatching systems include, but are not limited to, those available under the tradenames Spectraflash® (Datacolor International, Lawrenceville, NJ); Coloreye
  • Colorants may be added to the grout compositions manually, or advantageously may be added to the grout compositions using commercially available tinting equipment. Tint formulations to achieve a desired color are volume based, with a base unit of 1/48 of an ounce. Thus, if provided with a tint formula of 3E + 3V, one of ordinary skill in the art would recognize that 3/48 of an ounce of the universal colorant having the designation "E” should be added, in combination with 3/48* of an ounce of the universal colorant having the designation "V" to achieve the color described by the formulation.
  • tint dispensers that may either manually dispense the indicated amount, or, may do so automatically in response to color matching software, or upon the provision of the desired formula.
  • Examples of commercially available tinting equipment include any of those available from Red Devil, Generic Systems, Chameleon, and Charles Ross & Son, as well as those available under the trade designations Banco & MidiGiant (Corob, Ulvila, Finland), Harbil® Tintmaster, Accutinter or Blendorama (Fluid Management, Wheeling, IL); and ColorKing (Disti-Kleen, Irvinton, NJ)
  • the grout compositions may be agitated manually or by using any known means of agitation, including magnetic plates, rotary stirring means, such as blending or mixing bars, capable of achieving the stable uniform tinting of the grout composition.
  • a sufficient amount of shear thinning has been found to be provided to the present inventive grout compositions to achieve uniform dispersion by agitating the grout compositions on any of the many commercially available paint shakers.
  • such shakers may be sized for one or more containers, of one or more sizes, and are readily and easily operated by those of ordinary skill in the art, often only requiring insertion of the container and the push of a button to start the agitation motion.
  • these shakers often provide time guidelines depending on the type and/or size of the product, e.g., a 5 gallon bucket of latex paint may have a different recommended mixing time than a 1 gallon pail of latex paint, which may also have a different recommended mixing time than a 5 gallon pail of stucco.
  • Suppliers of tinting equipment typically may also supply commercially sized mixers, and any of these, or any other commercially available shaker, is/are suitable to agitate the present tintable grout compositions.
  • several such mixers are commercially available from Fluid Management, Inc., under the tradenames Harbil® 5G, Harbil® High Speed EZ Load, Miller GyroMixer and ProMix.
  • the present invention yet contemplates the convenience that could be provided by avoiding such steps, as could be achieved by providing a fandeck of color formulations suitable to tint the present invention grout compositions.
  • a fandeck of color formulations suitable to tint the present invention grout compositions.
  • the provision of such a fandeck would ensure that, by utilizing the provided tint formula, the color selected from the fandeck would be provided to the grout compositions.
  • the present invention thus also contemplates a kit for providing a tinted grout composition upon request, comprising a tintable one-part polymer grout composition according to the present invention, as well as instructions for tinting the same.
  • the instructions could include a fandeck of colors based upon one or more commercially available universal colorant systems, so that wherever the tintable grout compositions was purchased, it is likely that the purchaser would have several ready formulated color choices to select from.
  • a plurality of universal colorants may also be included within the kit, and at least one fandeck of colors provided based upon the same.
  • the following test procedures are suitable for use in the following examples: Tint dispersion will be measured by using a Spectraflash® 600 Plus spectrophotometer. More specifically, six measurements will be taken with each tinted grout sample with the maximum difference between any two readings reported (a dE value of 0 indicates no difference in color throughout a sample).
  • a grout composition that attains a tint dispersion of 1.5 or 1.0, or even about 0.5, will be considered to be substantially uniformly tinted as that phrase is used herein.
  • Tint stability will be measured by visually inspecting the tinted grout separation of the tints from the grout matrix, after oven accelerated aging.
  • a grout will be considered to exhibit tint stability if no visible separation of the tint from the grout composition occurs for a time period of at least about 4 weeks, when the tinted grout composition is subjected to accelerated aging temperatures i.e. a temperature of at least about 50° C.
  • Shrinkage/Crack resistance will be measured by applying the grout compositions to joint spaces up to 1/4" wide, allowing the grout to dry and recording any visually apparent cracks or sinking at joint intersections that occur(s).
  • Water resistance will be tested by immersing a 1 in diameter disk, l ⁇ " thick of dried grout in water and visually monitoring the impact of the water immersion at regular time intervals. Sample may also be tested for hardness or strength after the period of immersion. Water resistance may also be measured and evaluated according to the American National Standard Specifications for standard and polymer modified cement grouts, ANSI Al l 8.6 and A118.7. Stain Resistance will be measured and evaluated according to the Ceramic Tile Institute Stain Test CTI-T-72, but modified to include additional staining materials (beyond what is specified in the procedure). Grout compositions scoring an average of 2 or lower are considered stain resistant according to this method.
  • Tensile Strength will be measured and evaluated according to the American National Standard Specifications for standard and polymer modified cement grouts, ANSI A118.6 and Al 18.7, using a l A" dog bone sample rather than the specified sample size. Flexural Strength will be measured and evaluated according to the American National Standard Specifications for standard and polymer modified cement grouts, ANSI Al 18.6 and Al 18.7, using a V ⁇ " X Vi" bar sized sample rather than the specified sample size. Installation performance was measured and rated according to ASTM Method C 627- 76 Evaluating Ceramic Floor Tile Installation Systems. Shore A hardness was measured using a Shore A durameter. If the indenter completely penetrates the sample, a reading of 0 is obtained, and if no penetration occurs, a reading of 100 results. Samples capable of achieving an average Shore A hardness reading of at least about 50, or at least about 60, or even at least about 75 after being submerged in water for 7 days, are considered to be "water resistant" as that term is used herein.
  • Example 1 A sanded grout composition embodying certain aspects of the present invention was prepared according to the following Formula I by adding the components, in the order and amounts listed, to an appropriate mixing container: Formula I
  • this embodiment of the inventive grout composition also met the water absorption, tensile strength, and flexural strength property requirements for standard cement grout. More particularly, this particular grout composition had the following properties as measured by ANSI118.6:
  • Example 2 A sanded grout composition embodying certain aspects of the present invention was prepared according to the following Formula II by adding the components, in the order and amounts listed, to an appropriate mixing container: Formula II
  • Example 3 An unsanded grout composition embodying certain aspects of the present invention was prepared according to the following Formula III by adding the components, in the order and amounts listed, to an appropriate mixing container: Formula III
  • the above components were added to a container in the order recited and mixed after each addition with a KitchenAid mixer for at least one minute, with the exception that, after the addition of the fibers (Arbocel® and Lapinus), the mixture was mixed for at least about 5 minutes.
  • the resulting unsanded grout composition is expected to have a measured viscosity of 100,000 cps, and to be stably and uniformly tintable by the method of the present invention.
  • each of the samples were tinted with DeGussa Colortrend 888 tints according to the formulations 3E + 3V (3/48* oz phthalo blue and 3/48* oz magenta to provide purple); 3T + 3R (3/48 lh oz medium yellow and 3/48* oz organic red to provide orange) and 2D + 6E + 2T (2/48* oz phthalo green, 6/48* oz phthalo blue and 2/48* oz medium yellow to provide blue/green).
  • Tints were dispensed with a 22PD automatically dispensing tint dispenser (Fluid Management, Inc.), and the tinted grout agitated utilizing either a Miller Model G paint shaker, or a Harbil 5G HD, depending on the type of container. That is, the Miller paint shaker is suitable for metal cans, whereas the Harbil can accept only plastic containers. All samples were shaken for 3 minutes, turned over and shaken for another 3 minutes. The samples were then tested for color dispersion and tint stability, as described above. The results are provided in the tables below.
  • the Formula I grout composition and the six competitive samples were tested for shrinkage/crack resistance by applying the grout compositions to joint spaces up to 1/4" wide, allowing the grout to dry and recording any visually apparent cracks or sinking at joint intersections that occur(s). The results of this testing are provided below. Generally speaking, none of the six commercially available products are capable of being applied in joint spaces larger than 1/8" of without shrinkage or cracking.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
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  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
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  • Paints Or Removers (AREA)

Abstract

La présente invention a trait à une composition de coulis simple à base de polymères apte à une teinture de toute couleur souhaitée à la demande, ainsi qu'à un procédé de teinture de la composition de coulis. De manière avantageuse, les compositions de coulis simples à base de polymères peuvent être teintées au moyen d'une pluralité de colorants universels disponibles dans le commerce, selon des liasses de couleurs à base desdits colorants, ou par la mise à la teinte visuelle ou automatisée. De même, comme il est possible d'utiliser des colorants universels, l'équipement utilisé pour la teinture et l'agitation de la peinture pour fournir toute couleur souhaitée peut être employé pour les compositions de coulis de la présente invention. L'invention a également trait à une trousse comportant la composition de coulis apte à la teinture et le mode d'emploi pour la teinture de la composition de coulis selon le procédé.
PCT/US2004/040325 2003-12-05 2004-12-02 Compositions de coulis a base de polymeres WO2005056489A1 (fr)

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AU2004297194A AU2004297194B2 (en) 2003-12-05 2004-12-02 Polymer grout compositions
MXPA06006113A MXPA06006113A (es) 2003-12-05 2004-12-02 Composiciones de mortero de polimero.
CA2549165A CA2549165C (fr) 2003-12-05 2004-12-02 Compositions de coulis a base de polymeres

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US10/729,116 2003-12-05
US10/729,630 2003-12-05
US10/729,630 US7303068B2 (en) 2003-12-05 2003-12-05 Polymer grout compositions
US10/729,116 US7005462B2 (en) 2003-12-05 2003-12-05 Polymer grout compositions

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WO2011093974A1 (fr) * 2010-01-28 2011-08-04 Custom Building Products, Inc. Composition résistante à l'eau à durcissement rapide pour joints, charges et revêtements épais
EP2508580A1 (fr) * 2011-04-04 2012-10-10 Custom Building Products, Inc. Composition résistante à l'eau à durcissement rapide pour injections, charges et revêtements épais
US8357238B2 (en) 2010-01-28 2013-01-22 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings
US8876966B2 (en) 2010-01-28 2014-11-04 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings

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GB975587A (en) * 1961-10-06 1964-11-18 Chem Fab Grunau G M B H A composition for covering or filling cavities and sealing joints
US3967429A (en) * 1972-11-08 1976-07-06 Tile Council Of America, Inc. Method of grouting using specific mortar composition
DE3712382A1 (de) * 1987-04-11 1988-10-27 Rigips Gmbh Verfahren und masse zum verspachteln der fuge von gegeneinandergestossenen gipskartonplatten
DE3826877A1 (de) * 1988-08-08 1990-02-15 Pci Polychemie Augsburg Gmbh Verformungsfaehige, schwundarme fuell- und fugenmasse und deren anwendung
US5336318A (en) * 1990-09-17 1994-08-09 United States Gypsum Company Clay-free, asbestos-free and glass microbubble-free drying type joint compounds
EP0857772A1 (fr) * 1997-02-06 1998-08-12 Wacker-Chemie GmbH Compositions de jointoiement à coefficient d'élasticité élevé
WO2001077242A2 (fr) * 2000-04-12 2001-10-18 Bostik Findley Ltd. Adhesif resistant a l'eau

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US5830934A (en) * 1995-10-27 1998-11-03 Reichhold Chemicals, Inc. Colloidally stabilized emulsion polymer
EP1558539A4 (fr) * 2002-10-02 2008-03-26 Sang-Woon Kwak Coulis chimique non retrecissant a viscosite elevee

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Publication number Priority date Publication date Assignee Title
GB975587A (en) * 1961-10-06 1964-11-18 Chem Fab Grunau G M B H A composition for covering or filling cavities and sealing joints
US3967429A (en) * 1972-11-08 1976-07-06 Tile Council Of America, Inc. Method of grouting using specific mortar composition
DE3712382A1 (de) * 1987-04-11 1988-10-27 Rigips Gmbh Verfahren und masse zum verspachteln der fuge von gegeneinandergestossenen gipskartonplatten
DE3826877A1 (de) * 1988-08-08 1990-02-15 Pci Polychemie Augsburg Gmbh Verformungsfaehige, schwundarme fuell- und fugenmasse und deren anwendung
US5336318A (en) * 1990-09-17 1994-08-09 United States Gypsum Company Clay-free, asbestos-free and glass microbubble-free drying type joint compounds
EP0857772A1 (fr) * 1997-02-06 1998-08-12 Wacker-Chemie GmbH Compositions de jointoiement à coefficient d'élasticité élevé
WO2001077242A2 (fr) * 2000-04-12 2001-10-18 Bostik Findley Ltd. Adhesif resistant a l'eau

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011093974A1 (fr) * 2010-01-28 2011-08-04 Custom Building Products, Inc. Composition résistante à l'eau à durcissement rapide pour joints, charges et revêtements épais
US8349068B2 (en) 2010-01-28 2013-01-08 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings
US8357238B2 (en) 2010-01-28 2013-01-22 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings
US8876966B2 (en) 2010-01-28 2014-11-04 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings
AU2010344141B2 (en) * 2010-01-28 2015-03-26 Custom Building Products, Inc. Rapid curing water resistant composition for grouts, fillers and thick coatings
EP2508580A1 (fr) * 2011-04-04 2012-10-10 Custom Building Products, Inc. Composition résistante à l'eau à durcissement rapide pour injections, charges et revêtements épais

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MXPA06006110A (es) 2006-08-11
MXPA06006113A (es) 2006-08-11
AU2004297194B2 (en) 2009-11-19
CA2549166C (fr) 2012-06-12
AU2004297204A1 (en) 2005-06-23
CA2549165A1 (fr) 2005-06-23
CA2549165C (fr) 2012-07-17
CA2549166A1 (fr) 2005-06-23
AU2004297204B2 (en) 2010-09-16
AU2004297194A1 (en) 2005-06-23
WO2005056490A1 (fr) 2005-06-23

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