WO2005056490A1 - Polymer grout compositions - Google Patents
Polymer grout compositions Download PDFInfo
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- WO2005056490A1 WO2005056490A1 PCT/US2004/040410 US2004040410W WO2005056490A1 WO 2005056490 A1 WO2005056490 A1 WO 2005056490A1 US 2004040410 W US2004040410 W US 2004040410W WO 2005056490 A1 WO2005056490 A1 WO 2005056490A1
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- 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
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- 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
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- 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
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- 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, one-part polymer grout compositions that exhibit a variety of advantageous properties due at least in part to the inclusion therein of a silanated polymer. More particularly, the present grout compositions can be water resistant and stain resistant and in certain embodiments, even shrink and/or crack resistant so as to be suitable for use in horizontal applications, in damp or even wet, environments.
- one-part polymer grout is the only one that offers the convenience of being available in a pre-mixed state. That is, whereas one-part polymer grout hardens upon drying, the other types of grouts cure 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. Any unused amounts cannot be reconstituted.
- one-part polymer grouts thus provide a significant convenience to tile installers, those currently in the marketplace may not be suitable for use in all applications.
- many commercially available one-part polymer grouts are not sufficiently water resistant for use in extremely wet environments, such as e.g., the surfaces of a shower or bathroom or kitchen floors.
- one- part polymer grouts may be susceptible to staining, as may be caused by mold or other microbial infestation or growth, as could certainly occur absent the application of a sealer on top of the hardened grout.
- the application of sealer represents and an additional time requirement, which may be undesirable to those seeking the convenience otherwise offered by one-part polymer grout.
- one-part polymer grouts can be susceptible to shrinkage or cracking, further potentially limiting their applicability to drier environments or to uses with tile that does not absorb substantial amounts of water itself, such as porcelain tile.
- one-part polymer grout compositions would be available that would be suitable for use in a wider variety of applications, i.e., whether horizontal, vertical, load- bearing, moist, wet, etc.
- one-part polymer grouts could be improved if they could be provided with stain resistance, advantageously to a degree such that application of a sealer over the applied grout could be avoided.
- the present invention relates to novel one-part polymer grout compositions that can be substantially water and/or stain resistant.
- the grout compositions are also very strong, capable of meeting or even exceeding strength standards for cement grouts.
- the grout compositions may further be substantially resistant to shrinkage and/or cracking, even when applied in joint spaces up to 1/4" wide, and in yet other embodiments may be tintable by any standard paint tinting equipment.
- the present grout compositions may be utilized in a greater number of environments than conventional one-part polymer grouts while also providing enhanced convenience in any such use.
- the present invention provides a one-part polymer grout comprising a silanated polymer in an amount effective to render the dried grout water and/or stain resistant.
- the silanated polymer may desirably be a silanated acrylic latex, or in some embodiments, may be a silanated styrene acrylic latex.
- the present grout compositions are expected to exhibit at least some degree of resistance to shrinkage and/or cracking, this property of the present grout compositions may be enhanced in embodiments where the same may be desired via the inclusion of amounts of at least one fiber filler.
- the stain resistant aspect of the present grout compositions may also be enhanced via inclusion of one or more antimicrobial agents or stain resistant additives.
- the grout compositions may further comprise an amount of rheology modifying fillers.
- the term "grout” is meant to indicate a composition, filled or unfilled, 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.
- the phrase "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.
- 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.
- 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.
- 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.
- 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 comprising a silanated polymer that provide several advantages over conventional one-part polymer grout compositions.
- the present grout compositions are surprisingly strong, as well as being substantially water, stain and in certain embodiments shrinkage and/or crack 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.
- the present grout compositions may be utilized in applications wherein the use of conventional one-part polymer grouts had previously been contraindicated.
- the present grout compositions may be used with tiles formed from any material.
- the present grout compositions are expected to be useable with tiles made from any material, with substantially no shrinking or cracking. Rendering the present grout compositions even more useful and advantageous is the fact that, if desired, the present grout compositions may be rendered 'tintable' . That is, in certain embodiments of the present invention, the present grout compositions may surprisingly be tinted with paint tinting agents, according to any color deck, at a point of sale and agitated with standard paint shaking equipment to provide a stable uniformly tinted grout composition.
- the present invention thus provides a one-part polymer grout composition comprising a sinlatated polymer.
- 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 and water and stain resistance described herein, although for certain embodiments it may be advantageous or desirable that the silanated polymer have a minimum film formation temperature of at least about 20°F, or a T g greater than about 30°F so that any grout residue that may be present on the tile surface after installation can be cleaned off easily.
- One example of a particular class of polymers that may advantageously be employed in the present grout compositions are acrylics and acrylic dispersions, since acrylic latexes/dispersions can tend to be stronger and more water resistant than other types of polymers.
- silanated acrylic latexes are readily commercially available, such as those commercially available under the trade designations Rhoximat® DS931 (Rhodea North America, Cranbury, NJ) NX2835 (BASF Inc., Charlotte, NC), 13057 (Scott Bader, Northamptonshire, England).
- Rhoximat® DS931 Rhodea North America, Cranbury, NJ
- NX2835 BASF Inc., Charlotte, NC
- 13057 Scott Bader, Northamptonshire, England
- the invention is not so limited, as any known polymer having monomeric units comprising functionality reactive with a silane moiety, SiR 3 , may be modified to be silanated and then polymerized, according to any methodology known to those of ordinary skill in the art, to provide a silanated polymer in accordance with the present invention.
- silanated polymers e.g., silanated polymers
- silanated acrylic latexes 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. 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.
- such a dispersion it will be stabilized hybrid dispersion with enhanced interaction between the urethane and acrylic moieties, rather than a simple blend.
- Many such stabilized hybrid dispersions are commercially available, with but a few examples of these being any of those available under the trade designations Hybridur® (Air Products and Chemicals Inc., Allentown, PA) or NeoPac® (grades E125 and El 14, NeoResins, Wilmington, MA).
- 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%.
- inventive one-part polymer grout compositions comprising a silanated polymer are surprisingly strong, e.g., 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.
- the 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 present grout compositions provide significant advancement to the construction and home improvement industries, while even providing a potential cost and time savings in their application and use.
- the present one-part polymer grouts may be even further enhanced in order to provide additional advantages in their use and application.
- the present grout compositions may include amounts of fiber fillers, that can not only improve the cohesiveness of the grout compositions upon drying so that visual cracking can be minimized or eliminated, but also, may render the grout compositions tintable at a point of sale, as described in commonly assigned co-pending patent application no.
- Fibers of any material are believed to be capable of providing at least some amount of rheology modification and/or mixing facilitation, or assist in shrinkage/crack resistance, 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. Rettenmaier USA, Schoolcraft, MI.
- 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 if enhanced shrinkage and/or crack resistance is desired.
- 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 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 6 wt% 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 imparting at least minimal improvement in tint dispersion in the present grout compositions.
- each type of fiber may be included in the combination in an amount according to the ranges provided herein.
- the grout compositions are believed to be substantially water and/or stain resistant merely due to the inclusion therein of a silanated polymer, the stain resistance of the present grout compositions may also be further enhanced. In applications where such enhancement in the properties is desired, e.g. as may be the case for extremely wet application sites, in application sites where mold and mildew are otherwise known to proliferate, or application sites where contact with stain causing agents may be anticipated, the present grout compositions may further comprise effective amounts of anti-microbial and/or stain resistance additives.
- 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%.
- stain 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 Aquabead® 325E from Micro Powders, Tarrytown, NY; and polyurethane dispersions such as NeoResR9649 or 9699 also from Neoresins.
- Teflon powders such as Zonyl® MP1200 from DuPont
- Useful amounts of each of these stain resistance additives are well known and/or readily available, and generally speaking can range from about 0.5 wt% to about 10 wt%, about 1 wt% to about 6 wt%, or from about 1.5 wt% to about 4 wt% for the Teflon powders and wax dispersions.
- 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 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 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).
- T-Det® N407 and Triton® XI 00 Hardcros Chemicals, Inc., Kansas City, Kansas and Rohm and Haas, respectively.
- 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%.
- the present grout composition may further comprise any of the components otherwise found in conventional one-part polymer grout compositions.
- the present grout compositions may include such conventional components as 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 any fiber fillers and/or 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, EL) is but one example of a plasticizer suitable from use in the present grout compositions, if desired.
- Suitable amounts 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 wt% to about 1.5 wt%.
- the present strong, water and stain resistant 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.
- sanded grout compositions embodying features of the present invention 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 following test procedures are suitable for use in the following examples: Water resistance will be tested by immersing a 1 in diameter disk, i " 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 A118.6 and A118.7.
- 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).
- 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 W 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 W x W 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 compositions 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
- 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, (Wollastocoat®, Arbocel® and Lapinus), the mixture was mixed for at least about 5 minutes.
- the resulting grout composition is expected to have a measured viscosity of 625,000 cps, and is further expected to meet the water absorption, tensile strength, and flexural strength property requirements for standard cement grout.
- 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.
- Comparative Example 1 The grout compositions according to Formulas I and II, above, were tested according to ANSI 118.6 for water absorption, along side of three commercially available one-part grout compositions, Premix Ceramic Tile Adhesive and Grout, sanded and unsanded, commercially available from Tile Perfect, Aurora, IL and Custom Pre-Mixed Tile Grout, commercially available from Custom Building Products, Seal Beach, CA. Two samples of each grout composition were tested. The results of this comparison are provided below in Table 3
- 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* 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.
Abstract
Description
Claims
Priority Applications (3)
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MXPA06006110A MXPA06006110A (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions. |
AU2004297204A AU2004297204B2 (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions |
CA2549166A CA2549166C (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions |
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US10/729,116 | 2003-12-05 | ||
US10/729,116 US7005462B2 (en) | 2003-12-05 | 2003-12-05 | Polymer grout compositions |
US10/729,630 US7303068B2 (en) | 2003-12-05 | 2003-12-05 | Polymer grout compositions |
US10/729,630 | 2003-12-05 |
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WO2005056490A1 true WO2005056490A1 (en) | 2005-06-23 |
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PCT/US2004/040410 WO2005056490A1 (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions |
PCT/US2004/040325 WO2005056489A1 (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions |
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PCT/US2004/040325 WO2005056489A1 (en) | 2003-12-05 | 2004-12-02 | Polymer grout compositions |
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AU (2) | AU2004297204B2 (en) |
CA (2) | CA2549166C (en) |
MX (2) | MXPA06006110A (en) |
WO (2) | WO2005056490A1 (en) |
Families Citing this family (4)
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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 |
US8349068B2 (en) | 2010-01-28 | 2013-01-08 | Custom Building Products, Inc. | Rapid curing water resistant composition for grouts, fillers and thick coatings |
CA2773799C (en) * | 2011-04-04 | 2019-09-24 | Custom Building Products, Inc. | Rapid curing water resistant composition for grouts, fillers and thick coatings |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3826877A1 (en) * | 1988-08-08 | 1990-02-15 | Pci Polychemie Augsburg Gmbh | Deformable, low-shrinkage filling and grouting composition and its application |
WO1997015603A1 (en) * | 1995-10-27 | 1997-05-01 | Reichhold Chemicals, Inc. | Colloidally stabilized emulsion polymer |
EP0857772A1 (en) * | 1997-02-06 | 1998-08-12 | Wacker-Chemie GmbH | Joint sealing compounds with high resilience |
WO2001077242A2 (en) * | 2000-04-12 | 2001-10-18 | Bostik Findley Ltd. | Water-resistant grout and title adhesive composition |
WO2004031094A2 (en) * | 2002-10-02 | 2004-04-15 | Sang-Woon Kwak | Non-shrink high viscosity chemical grout |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE623314A (en) * | 1961-10-06 | |||
US3967429A (en) * | 1972-11-08 | 1976-07-06 | Tile Council Of America, Inc. | Method of grouting using specific mortar composition |
DE3712382C2 (en) * | 1987-04-11 | 1995-08-31 | Rigips Gmbh | Process and joint filler for filling the joint of gypsum plasterboards that have collided with one another |
CA2065231A1 (en) * | 1990-09-17 | 1992-03-18 | Peter M. Attard | Clay-free, asbestos-free and glass microbubble-free joint compounds |
-
2004
- 2004-12-02 AU AU2004297204A patent/AU2004297204B2/en not_active Ceased
- 2004-12-02 MX MXPA06006110A patent/MXPA06006110A/en active IP Right Grant
- 2004-12-02 WO PCT/US2004/040410 patent/WO2005056490A1/en active Application Filing
- 2004-12-02 WO PCT/US2004/040325 patent/WO2005056489A1/en active Application Filing
- 2004-12-02 AU AU2004297194A patent/AU2004297194B2/en not_active Ceased
- 2004-12-02 MX MXPA06006113A patent/MXPA06006113A/en active IP Right Grant
- 2004-12-02 CA CA2549166A patent/CA2549166C/en not_active Expired - Fee Related
- 2004-12-02 CA CA2549165A patent/CA2549165C/en not_active Expired - Fee Related
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3826877A1 (en) * | 1988-08-08 | 1990-02-15 | Pci Polychemie Augsburg Gmbh | Deformable, low-shrinkage filling and grouting composition and its application |
WO1997015603A1 (en) * | 1995-10-27 | 1997-05-01 | Reichhold Chemicals, Inc. | Colloidally stabilized emulsion polymer |
EP0857772A1 (en) * | 1997-02-06 | 1998-08-12 | Wacker-Chemie GmbH | Joint sealing compounds with high resilience |
WO2001077242A2 (en) * | 2000-04-12 | 2001-10-18 | Bostik Findley Ltd. | Water-resistant grout and title adhesive composition |
WO2004031094A2 (en) * | 2002-10-02 | 2004-04-15 | Sang-Woon Kwak | Non-shrink high viscosity chemical grout |
Also Published As
Publication number | Publication date |
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MXPA06006110A (en) | 2006-08-11 |
CA2549166C (en) | 2012-06-12 |
WO2005056489A1 (en) | 2005-06-23 |
AU2004297204B2 (en) | 2010-09-16 |
MXPA06006113A (en) | 2006-08-11 |
CA2549165A1 (en) | 2005-06-23 |
AU2004297204A1 (en) | 2005-06-23 |
AU2004297194B2 (en) | 2009-11-19 |
CA2549165C (en) | 2012-07-17 |
AU2004297194A1 (en) | 2005-06-23 |
CA2549166A1 (en) | 2005-06-23 |
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