WO2024091548A1 - Composition de composé à joint améliorée par des fibres - Google Patents

Composition de composé à joint améliorée par des fibres Download PDF

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Publication number
WO2024091548A1
WO2024091548A1 PCT/US2023/035885 US2023035885W WO2024091548A1 WO 2024091548 A1 WO2024091548 A1 WO 2024091548A1 US 2023035885 W US2023035885 W US 2023035885W WO 2024091548 A1 WO2024091548 A1 WO 2024091548A1
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WO
WIPO (PCT)
Prior art keywords
joint compound
compound composition
less
fiber
microns
Prior art date
Application number
PCT/US2023/035885
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English (en)
Inventor
Charles Miner
Edwin ESCOBAR
Paul Palyukh
Original Assignee
Proform Finishing Products, Llc
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Filing date
Publication date
Application filed by Proform Finishing Products, Llc filed Critical Proform Finishing Products, Llc
Publication of WO2024091548A1 publication Critical patent/WO2024091548A1/fr

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Classifications

    • 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
    • C09D101/00—Coating compositions based on cellulose, modified cellulose, or cellulose derivatives
    • C09D101/02—Cellulose; Modified cellulose
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C08L1/02—Cellulose; Modified cellulose
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C08L1/08—Cellulose derivatives
    • C08L1/26—Cellulose ethers
    • C08L1/28—Alkyl ethers
    • 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
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C09D1/06—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement
    • C09D1/08—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement with organic additives
    • 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
    • C09D101/00—Coating compositions based on cellulose, modified cellulose, or cellulose derivatives
    • C09D101/08—Cellulose derivatives
    • C09D101/26—Cellulose ethers
    • C09D101/28—Alkyl ethers

Definitions

  • Joint compound compositions are commonly used in the building industry in combination with gypsum wallboards.
  • gypsum wallboards are affixed to a support structure, typically using screws or nails.
  • the gaps between adjacent gypsum wallboards are typically referred to as joints.
  • joints In order to achieve a smooth, visually appealing surface, the joints between the gypsum wallboards, any cracks, screw holes, and/or nail holes should be concealed.
  • joint compound compositions are utilized for such purposes.
  • one such type of joint compound composition is a drying-type joint compound.
  • the composition is mixed for a specific time with water prior to use and is then applied.
  • the water evaporates and the compound dries to form a relatively hard cementitious material.
  • the joint compound composition may still exhibit some deficiencies.
  • the joint compound composition may have deficient strength and may be vulnerable to crack formation over time.
  • the joint compound composition may comprise additives that may be harmful to the environment and/or people.
  • a joint compound composition comprises water, a cementitious filler, and natural fiber, wherein the natural fiber is present in the joint compound composition in an amount from about 0.05 wt.% to about 20 wt.%, wherein the joint compound composition has a viscosity from about 100 Bll to about 1000 BU.
  • a method of making a joint compound composition comprises: combining water, a cementitious filler, and the natural fiber, wherein the natural fiber is present in the joint compound composition in an amount from about 0.05 wt.% to about 20 wt.%, wherein the joint compound composition has a viscosity from about 100 BU to about 1000 BU, applying the joint compound composition to a joint between adjacent gypsum wallboards, allowing the joint compound composition to dry and cure, and applying a tape to a portion of the joint compound composition or to the entirety of the joint compound composition.
  • the present invention is directed to a joint compound composition.
  • the joint compound composition may include water, a cementitious filler, and fiber.
  • the present inventors have discovered that the particular joint compound composition as disclosed herein provides various advantages, in particular when utilized within the building industry. For instance, the joint compound composition may have enhanced flexural strength, improved drying time, enhanced tensile strength, enhanced compressive strength, and increased resistance to crack formation (i.e., crack resistance).
  • the joint compound composition as disclosed herein may also exhibit other beneficial properties.
  • the joint compound composition may also result in one or more of reduced cratering, reduced shrinking, greater sag resistance, and excellent workability.
  • each numerical value e.g., weight percentage, concentration
  • each numerical value should be read as modified by the term “about” (unless already expressly so modified) and then read again as not to be so modified.
  • a value of “100” is to be understood as disclosing “100” and “about 100”.
  • the joint compound composition may include fiber.
  • the joint compound composition may include a natural fiber.
  • the natural fiber may include cork fiber, hemp fiber, cotton fiber, kenaf fiber, jute fiber, sisal fiber, ramie fiber, roselle fiber, flax fiber, sunn fiber, coir fiber, pina fiber, milkweed fiber, linen fiber, urena fiber, or a combination thereof.
  • the natural fiber may include cellulose fiber.
  • the cellulose fiber may be derived from wood fiber, cork fiber, hemp fiber, cotton fiber, kenaf fiber, jute fiber, sisal fiber, ramie fiber, roselle fiber, flax fiber, sunn fiber, coir fiber, pina fiber, milkweed fiber, linen fiber, urena fiber, or a combination thereof.
  • the joint compound composition of the present disclosure may include one or more of the aforementioned fibers in any combination thereof.
  • the joint compound composition may include natural fiber, the natural fiber comprising more than one type of natural fiber.
  • the joint compound composition may include a natural fiber which may include cellulose fiber, such as microcellulose fiber and/or nanocellulose fiber.
  • the cellulose fiber may be particularly suitable for use in a joint compound composition.
  • the cellulose fiber may enhance the tensile strength, enhance the compressive strength, and increase the crack resistance of the joint compound composition.
  • the cellulose fiber may be physically and/or chemically modified.
  • the cellulose fiber may be physically modified by a mechanical treatment, a heat treatment, a UV modification treatment, a gamma irradiation treatment, a corona modification treatment, a plasma treatment, or a combination thereof.
  • a mechanical treatment may include refining the cellulose fiber.
  • the fibers may be subjected to mechanical compression and shearing.
  • the refining of the cellulose fiber may enhance the flexibility of the cellulose fiber and may enhance the bond strength between the cellulose fiber and the joint compound composition matrix.
  • the refining of the cellulose fiber may enhance the strength and crack resistance of the joint compound composition.
  • the cellulose fiber may have a Schopper-Riegler degree of refining from about 0 0 SR to about 90 0 SR, including all increments of 1 0 SR therebetween, such as about 0 0 SR or more, such as about 10 0 SR or more, such as about 20 0 SR or more, such as about 30 0 SR or more, such as about 40 0 SR or more, such as about 50 0 SR or more, such as about 60 0 SR or more, such as about 70 0 SR or more, such as about 80 0 SR or more, such as about 90 0 SR or less, such as about 80 0 SR or less, such as about 70 0 SR or less, such as about 60 0 SR or less, such as about 50 0 SR or less, such as about 40 0 SR or less, such as about 30 0 SR or less, such as about 20 0 SR or less.
  • the cellulose fibers may be chemically modified.
  • the cellulose fibers may be chemically modified by oxidation, carboxymethylation, succinylation, sulfonation, phosphorylation, esterification, polymer grafting, or a combination thereof.
  • the fiber e.g., cellulose fiber
  • the fiber may have a selectively chosen average fiber diameter.
  • an increase in the average fiber diameter of the fiber may increase the strength and crack resistance of the joint compound composition.
  • too much of an increase in the average fiber diameter of the fiber may result in a decreased number of fibers per unit volume in the joint compound composition, which may negatively affect the strength and crack resistance of the joint compound composition.
  • the average fiber diameter of the fiber may be selectively chosen to increase the strength and crack resistance of the joint compound composition while also maintaining a suitable number of fibers per unit volume in the joint compound composition.
  • the fiber may have an average fiber diameter of about 1 nanometer to about 100 microns, including all increments of 1 nanometer therebetween.
  • the average fiber diameter may be about 100 microns or less, such as about 75 microns or less, such as about 50 microns or less, such as about 45 microns or less, such as about 40 microns or less, such as about 35 microns or less, such as about 30 microns or less, such as about 25 microns or less, such as about 20 microns or less, such as about 15 microns or less, such as about 10 microns or less, such as about 5 microns or less, such as about 1 micron or less, such as about 900 nanometers or less, such as about 800 nanometers or less, such as about 600 nanometers or less, such as about 500 nanometers or less, such as about 300 nanometers or less, such as about 200 nanometers or less, such as about 100 nanometers or less, such as
  • the fiber may have an average fiber diameter of about 1 nanometer or more, such as about 5 nanometers or more, such as about 10 nanometers or more, such as about 20 nanometers or more, such as about 30 nanometers or more, such as about 40 nanometers or more, such as about 50 nanometers or more, such as about 100 nanometers or more, such as about 250 nanometers or more, such as about 500 nanometers or more, such as about 750 nanometers or more, such as about 1 micron or more, such as about 5 microns or more, such as about 10 microns or more, such as about 15 microns or more, such as about 20 microns or more, such as about 25 microns or more, such as about 30 microns or more, such as about 35 microns or more, such as about 40 microns or more, such as about 45 microns or more, such as about 50 microns or more, such as about 75 microns or more.
  • the aforementioned values may refer to a median fiber diameter of about 1
  • the fiber may have a selectively chosen average fiber length.
  • an increase in the average fiber length of the fiber may increase the strength of the joint compound composition, such as compressive strength, tensile strength, and flexural strength.
  • too much of an increase in average fiber length may result in decreased strength.
  • the decreased strength may be at least partially a result of weak bond strength between the fiber and the joint compound composition matrix.
  • the decreased strength may be at least partially a result of decreased fiber dispersion in the joint compound composition.
  • the average fiber length of the fiber may be selectively chosen to increase the strength of the joint compound composition while also maintaining a suitable fiber dispersion in the joint compound composition.
  • the fiber may have an average fiber length of about 5 nanometers to about 2000 microns, including all increments of 1 nanometer therebetween.
  • the fiber may have an average fiber length of less than about 1000 microns, such as about 500 microns or less, such as about 400 microns or less, such as about 300 microns or less, such as about 200 microns or less, such as about 150 microns or less, such as about 100 microns or less, such as about 75 microns or less, such as about 50 microns or less, such as about 45 microns or less, such as about 40 microns or less, such as about 35 microns or less, such as about 30 microns or less, such as about 25 microns or less, such as about 20 microns or less, such as about 15 microns or less, such as about 10 microns or less, such as about 5 microns or less, such as about 1 micron or less, such as about 900 nano
  • the fiber may have an average fiber length of about 5 nanometers or more, such as about 10 nanometers or more, such as about 20 nanometers or more, such as about 30 nanometers or more, such as about 40 nanometers or more, such as about 50 nanometers or more, such as about 100 nanometers or more, such as about 250 nanometers or more, such as about 500 nanometers or more, such as about 750 nanometers or more, such as about 1 micron or more, such as about 5 microns or more, such as about 10 microns or more, such as about 15 microns or more, such as about 20 microns or more, such as about 25 microns or more, such as about 30 microns or more, such as about 35 microns or more, such as about 40 microns or more, such as about 45 microns or more, such as about 50 microns or more, such as about 75 microns or more, such as about 100 microns or more, such as about 200 microns or more, such as about 300 micro
  • the fiber e.g., cellulose fiber
  • the fiber may have a selectively chosen water absorption capacity.
  • an increase in the water absorption capacity may reduce the occurrence of crack formation, reduce the severity of cracks when formed, provide for later joint compound composition hydration, and increase freeze-thaw durability of the joint compound composition.
  • too high of a water absorption capacity may result in decreased strength of the joint compound composition and/or the rapid deterioration of the fiber in the joint compound composition.
  • the water absorption capacity of the fiber may be selectively chosen to increase the durability of the joint compound composition while also maintaining enhanced strength.
  • the fiber e.g., cellulose fiber
  • the fiber may have a water absorption capacity of about 0.01 g FW/g fiber to about 30 g l-hO/g fiber, including all increments of 0.01 g FW/g fiber therebetween.
  • the fiber may have a water absorption capacity of about 0.01 g FW/g fiber or more, such as about 0.1 g FW/g fiber or more, such as about 1 g FW/g fiber or more, such as about 2 g F /g fiber or more, such as about 5 g FW/g fiber or more, such as about 8 g FW/g fiber or more, such as about 10 g FW/g fiber or more, such as about 15 g FW/g fiber or more, such as about 20 g FW/g fiber or more, such as about 25 g FW/g fiber or more.
  • the fiber may have a water absorption capacity of about 30 g FW/g fiber or less, such as about 25 g FW/g fiber or less, such as about 20 g FW/g fiber or less, such as about 15 g FW/g fiber or less, such as about 10 g FW/g fiber or less, such as about 8 g FW/g fiber or less, such as about 5 g FW/g fiber or less, such as about 2 g FW/g fiber or less, such as about 1 g FW/g fiber or less, such as about 0.1 g FW/g fiber or less.
  • the aforementioned values may also be expressed in the form of percentages, including any respective percentage of any water absorption capacity disclosed herein. For instance, 1 g FW/g fiber equates to fiber having a water absorption capacity of 100% by weight. Further, for instance, 2 g FW/g fiber equates to fiber having a water absorption capacity of 200% by weight.
  • one method of determining the water absorption capacity of the fiber involves preparing a sample of the fiber. Next, the fiber sample is weighed to determine its initial dry weight. Then, the fiber sample is submerged in water for a period of thirty minutes to one hour. Next, the fiber sample is removed from the water and allowed to drain. Then, the fiber sample is reweighed to determine the final weight of the fiber sample.
  • the water absorption capacity may be determined by calculating the final weight minus the initial weight to obtain a value, then dividing that value by the initial weight to obtain a second value, and then multiplying the second value by 100.
  • the fiber e.g., cellulose fiber
  • the fiber may have a selectively chosen pH.
  • an increase in the pH of the fiber may increase the water absorption capacity of the fiber which may reduce the occurrence of crack formation, reduce the severity of cracks when formed, provide for later joint compound composition hydration, and increase the freeze-thaw durability of the joint compound composition.
  • a pH that is too high may result in decreased strength of the joint compound composition and/or the rapid deterioration of the fiber in the joint compound composition.
  • the pH of the fiber may be selectively chosen to increase the durability of the joint compound composition while also maintaining enhanced strength.
  • the pH of the fiber may be determined by AOAC 943.02.
  • the fiber e.g., cellulose fiber
  • the fiber may have a pH of about 3 to about 10, such as a pH of about 3 or more, such as a pH of about 4 or more, such as a pH of about 4.5 or more, such as a pH of about 5 or more, such as a pH of about 5.5 or more, such as a pH of about 6 or more, such as a pH of about 6.5 or more, such as a pH of about 7 or more, such as a pH of about 7.5 or more, such as a pH of about 8 or more.
  • a pH of about 3 or more such as a pH of about 4 or more, such as a pH of about 4.5 or more, such as a pH of about 5 or more, such as a pH of about 5.5 or more, such as a pH of about 6 or more, such as a pH of about 6.5 or more, such as a pH of about 7 or more, such as a pH of about 7.5 or more, such as a pH of about 8 or more.
  • the fiber may have a pH of about 10 or less, such as about 9 or less, such as about 8 or less, such as about 7.5 or less, such as about 7 or less, such as about 6.5 or less, such as about 6 or less, such as about 5.5 or less, such as about 5 or less, such as about 4 or less.
  • the fiber may have a selectively chosen cellulose content.
  • the fiber may be and/or include high purity cellulose fiber.
  • “high purity” cellulose fiber refers to cellulose fiber with a cellulose content above 90 wt.%.
  • the fiber e.g., cellulose fiber
  • the fiber may have a cellulose content of about 20 wt.% to 100 wt.%, including all increments of 0.1 wt.% therebetween.
  • the fiber may have a cellulose content of about 20 wt.% or more, such as about 30 wt.% or more, such as about 40 wt.% or more, such as about 50 wt.% or more, such as about 60 wt.% or more, such as about 70 wt.% or more, such as about 80 wt.% or more, such as about 85 wt.% or more, such as about 90 wt.% or more, such as about 95 wt.% or more, such as about 98 wt.% or more.
  • the fiber may have a cellulose content of less than 100 wt.%, such as about 98 wt.% or less, such as about 95 wt.% or less, such as about 90 wt.% or less, such as about 80 wt.% or less, such as about 70 wt.% or less, such as about 60 wt.% or less, such as about 50 wt.% or less, such as about 40 wt.% or less, such as about 30 wt.% or less.
  • the fiber e.g., cellulose fiber
  • the fiber may have a bulk density from about 0.01 g/cm 3 to about 2 g/cm 3 , such as about 0.01 g/cm 3 or more, such as about 0.05 g/cm 3 or more, such as about 0.1 g/cm 3 or more, such as about 0.15 g/cm 3 or more, such as about 0.2 g/cm 3 or more, such as about 0.3 g/cm 3 or more, such as about 0.4 g/cm 3 or more, such as about 0.5 g/cm 3 or more, such as about 0.6 g/cm 3 or more, such as about 0.7 g/cm 3 or more, such as about 0.8 g/cm 3 or more, such as about 0.9 g/cm 3 or more.
  • the fiber may have a bulk density of less than about 2 g/cm 3 , such as about 1 g/cm 3 or less, such as about 0.9 g/cm 3 or less, such as about 0.8 g/cm 3 or less, such as about 0.7 g/cm 3 or less, such as about 0.6 g/cm 3 or less, such as about 0.5 g/cm 3 or less, such as about 0.4 g/cm 3 or less, such as about 0.3 g/cm 3 or less, such as about 0.2 g/cm 3 or less, such as about 0.1 g/cm 3 or less.
  • the bulk density may be determined by ISO 60:197 and/or DIN EN ISO 60.
  • the fiber e.g., cellulose fiber
  • the particle size distribution of the fiber may be determined by ISO 4610:2001 and/or DIN EN ISO 4610.
  • a mesh size of 300 microns may retain from about 0.01 wt.% to about 1 wt.% of the fiber (e.g., cellulose fiber), such as about 0.01 wt.% or more, such as about 0.1 wt.% or more, such as about 0.2 wt.% or more, such as about 0.3 wt.% or more, such as about 0.4 wt.% or more, such as about 0.5 wt.% or more, such as about 0.6 wt.% or more, such as about 0.7 wt.% or more, such as about 0.8 wt.% or more, such as about 0.9 wt.% or more.
  • a mesh size of 300 microns may retain about 1 wt.% or less of the fiber, such as about 0.9 wt.% or less, such as about 0.8 wt.% or less, such as about 0.7 wt.% or less, such as about 0.6 wt.% or less, such as about 0.5 wt.% or less, such as about 0.4 wt.% or less, such as about 0.3 wt.% or less, such as about 0.2 wt.% or less, such as about 0.1 wt.% or less.
  • a mesh size of 100 microns may retain from about 5 wt.% to about 40 wt.% of the fiber, such as about 5 wt.% or more, such as about 10 wt.% or more, such as about 15 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more.
  • a mesh size of 100 microns may retain about 40 wt.% or less of the fiber, such as about 35 wt.% or less, such as about 30 wt.% or less, such as about 25 wt.% or less, such as about 20 wt.% or less, such as about 15 wt.% or less, such as about 10 wt.% or less.
  • a mesh size of 32 microns may retain from about 20 wt.% to about 90 wt.% of the fiber, such as about 20 wt.% or more, such as about 30 wt.% or more, such as about 40 wt.% or more, such as about 50 wt.% or more, such as about 60 wt.% or more, such as about 70 wt.% or more, such as about 80 wt.% or more.
  • a mesh size of 32 microns may retain about 90 wt.% or less of the fiber, such as about 80 wt.% or less, such as about 70 wt.% or less, such as about 60 wt.% or less, such as about 50 wt.% or less, such as about 40 wt.% or less, such as about 30 wt.% or less.
  • the fiber e.g., cellulose fiber
  • the fiber may have a D50 of about 1 micron or more, such as about 5 microns or more, such as about 10 microns or more, such as about 15 microns or more, such as about 25 microns or more, such as about 30 microns or more, such as about 35 microns or more, such as about 40 microns or more, such as about 45 microns or more, such as about 50 microns or more, such as about 75 microns or more.
  • the fiber may have a D50 of about 100 microns or less, such as about 75 microns or less, such as about 50 microns or less, such as about 45 microns or less, such as about 40 microns or less, such as about 35 microns or less, such as about 30 microns or less, such as about 25 microns or less, such as about 20 microns or less, such as about 15 microns or less, such as about 10 microns or less, such as about 5 microns or less, such as about 4 microns or less, such as about 1 micron or less.
  • the D50 of the fiber may be determined by a laser diffractometer such as a Microtrac S3500.
  • any and all of the natural fibers may have an average fiber diameter, average fiber length, water absorption capacity, pH, cellulose content, bulk density, particle size distribution (e.g., fiber retainment by mesh size and D50 value), or a combination thereof in any of the respective corresponding values disclosed herein.
  • any natural fiber of the present disclosure may have a cellulose content of about 60 wt.% or more.
  • the joint compound composition may include fiber (e.g., cellulose fiber) in an amount from about 0.01 wt.% to about 20 wt.%, including all increments of 0.01 wt.% therebetween.
  • the joint compound composition may include fiber in an amount of about 0.01 wt.% or more, such as about 0.05 wt.% or more, such as about 0.1 wt.% or more, such as about 0.2 wt.% or more, such as about 0.3 wt.% or more, such as about 0.4 wt.% or more, such as about 0.5 wt.% or more, such as about 0.6 wt.% or more, such as about 0.7 wt.% or more, such as about 0.8 wt.% or more, such as about 0.9 wt.% or more, such as about 1 wt.% or more, such as about 5 wt.% or more.
  • the joint compound composition may include fiber in an amount of about 20 wt.% or less, such as about 15 wt.% or less, such as about 10 wt.% or less, such as about 5 wt.% or less, such as about 1 wt.% or less, such as about 0.9 wt.% or less, such as about 0.8 wt.% or less, such as about 0.7 wt.% or less, such as about 0.6 wt.% or less, such as about 0.5 wt.% or less, such as about 0.4 wt.% or less, such as about 0.3 wt.% or less, such as about 0.2 wt.% or less, such as about 0.1 wt.% or less.
  • the aforementioned values may be based on the weight of the joint compound composition.
  • the aforementioned values may be based on the weight of the cementitious filler in the joint compound composition.
  • the joint compound composition may include water.
  • water may be present in an amount of at least 10 wt.%, such as at least 20 wt.%, such as at least 30 wt.%, such as at least 35 wt.%, such as at least 40 wt.%, such as at least 45 wt.%, such as at least 50 wt.% based on the weight of the joint compound composition.
  • the water may be present in an amount of 90 wt.% or less, such as 80 wt.% or less, such as 70 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less, such as 45 wt.% or less, such as 40 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may include a cementitious filler.
  • the cementitious filler may include limestone, calcium carbonate, calcium magnesium carbonate, calcium sulfate dihydrate, or a mixture thereof. In one embodiment, the cementitious filler may include calcium carbonate.
  • the cementitious filler may include calcium magnesium carbonate. In a further embodiment, the cementitious filler may include calcium sulfate dihydrate. In another further embodiment, the cementitious filler may include a mixture of at least two of calcium carbonate, calcium magnesium carbonate, and calcium sulfate dihydrate, such as a mixture of calcium carbonate and calcium magnesium carbonate, a mixture of calcium carbonate and calcium sulfate dihydrate, or a mixture of calcium magnesium carbonate and calcium sulfate dihydrate. In a further embodiment, the cementitious filler may include a mixture of calcium carbonate, calcium magnesium carbonate, and calcium sulfate dihydrate.
  • the cementitious filler may be present in an amount of at least 5 wt.%, such as at least 10 wt.%, such as at least 20 wt.%, such as at least 30 wt.%, such as at least 35 wt.%, such as at least 40 wt.%, such as at least 45 wt.%, such as at least 50 wt.% based on the weight of the joint compound composition.
  • the cementitious filler may be present in an amount of 70 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less, such as 45 wt.% or less, such as 40 wt.% or less based on the weight of the joint compound composition.
  • the aforementioned weight percentages may apply to a single cementitious filler used alone as well as a mixture of cementitious fillers.
  • the joint compound composition may include a mineral filler.
  • the mineral filler may include a silicate.
  • the silicate may be a nesosilicate, a sorosilicate, a cyclosilicate, an inosilicate, a phyllosilicate, a tectosilicate, or a mixture thereof.
  • the silicate may be a phyllosilicate.
  • the mineral filler may include kaolin, montmorillonite, vermiculite, perlite, illite, halloysite, talc, pyrophyllite, palygorskite, attapulgite clay, sepiolite, mica, or a mixture thereof.
  • the mineral filler may comprise mica, talc, pyrophyllite, or a mixture thereof.
  • the mineral filler may include mica.
  • the mineral filler may include talc.
  • the mineral filler may include pyrophyllite.
  • the mineral filler may include a mixture of at least two of mica, talc, and pyrophyllite.
  • the mineral filler may include a mixture of mica and talc.
  • the mineral filler may include a mixture of talc and pyrophyllite.
  • the mineral filler may include a mixture of mica and pyrophyllite.
  • the mineral filler may include a mixture of mica, talc, and pyrophyllite.
  • the joint compound composition may be substantially free of one or more mineral fillers. As used herein, “substantially free” refers to a mineral filler being present in the joint compound composition in an amount less than about 0.05% by weight. In one aspect, the joint compound composition may be free and/or substantially free of mica, pyrophyllite, and/or talc. In another aspect, the joint compound composition may be substantially free of mineral fillers. In this respect, the joint compound composition may contain less than 0.05% by weight of any mineral filler. In yet another aspect, the joint compound composition may contain no mineral fillers. In this respect, the joint compound composition may be free of mineral fillers.
  • mineral fillers such as mica and pyrophyllite have been traditionally used at least partially to enhance the crack resistance of a joint compound composition.
  • Such mineral fillers generally have a high silica content.
  • the reduction of the content of mineral filler in the joint compound composition may reduce the silica content of the joint compound composition.
  • the reduction of the silica content of the joint compound composition may result in a joint compound composition that is more environmentally friendly and/or presents decreased health risks when compared to a traditional joint compound composition.
  • any of the mineral fillers disclosed herein may be used in the joint compound composition of the present disclosure.
  • a mineral filler may be present in an amount of at least 0.01 wt.%, such as at least 0.05 wt.%, such as at least 0.1 wt.%, such as at least 0.5 wt.%, such as at least 1 wt.%, such as at least 2 wt.%, such as at least 5 wt.%, such as at least 8 wt.%, such as at least 10 wt.% based on the weight of the joint compound composition.
  • a mineral filler may be present in an amount of 30 wt.% or less, such as 25 wt.% or less, such as 20 wt.% or less, such as 15 wt.% or less, such as 13 wt.% or less, such as 11 wt.% or less, such as 10 wt.% or less, such as 8 wt.% or less, such as 6 wt.% or less, such as 5 wt.% or less, such as 2 wt.% or less, such as 1 wt.% or less, such as 0.5 wt.% or less, such as 0.1 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may include an elastomer.
  • the elastomer may be an elastomeric polyester, an elastomeric polyurethane, an elastomeric polyamide, an elastomeric copolymer, and the like, and a mixture thereof.
  • the elastomer may be a copolymer.
  • the copolymer may be a block copolymer, such as a substantially amorphous block copolymer having at least two blocks.
  • the blocks may include a monoalkenyl arene polymer at and at least one block of a saturated conjugated diene polymer.
  • the monoalkenyl arene block may include a styrene.
  • the styrene may include analogues and homologues, such as o-methyl styrene, p-methyl styrene, p-tert-butyl styrene, 2,3-dimethyl styrene, etc.
  • the conjugated diene blocks may include a homopolymer of a conjugated diene monomer, a copolymer of two or more conjugated diene monomers, or a copolymer of one or more of the diene monomers with another monomer in which the blocks are predominantly conjugated diene units.
  • the conjugated diene monomer may generally contain from 4 to 8 carbon atoms, such as 1 ,3-butadiene (butadiene), 2-methyl-1 ,3-butadiene, isoprene, 2,3-dimethyl-1 ,3-butadiene, 1 ,3- pentadiene (piperylene), 1 ,3-hexadiene, etc.
  • the amount of monoalkenyl arene blocks may vary but may typically constitute 5 wt.% or more, such as 10 wt.% or more, such as 20 wt.% or more, such as 30 wt.% or more, such as 40 wt.% or more to 85 wt.% or less, such as 70 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less, such as 40 wt.% or less, such as 35 wt.% or less, such as 30 wt.% or less of the copolymer.
  • the elastomer may include a styrene-diene block copolymer, such as styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, styrene-isoprene- styrene, etc.
  • styrene-diene block copolymer such as styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, styrene-isoprene- styrene, etc.
  • the elastomer may also include a styrene-olefin block copolymer, such as styrene-(ethylene-butylene), styrene-(ethylene-propylene), styrene- (ethylene-butylene)-styrene, styrene-(ethylene-propylene)-styrene, styrene- (ethylene-butylene)-styrene-(ethylene-butylene), styrene-(ethylene-propylene)- styrene-(ethylene-propylene), and styrene-ethylene-(ethylene-propylene)-styrene.
  • the elastomer includes styrene-butadiene.
  • the elastomer may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the elastomer may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1.4 wt.% or less, such as 1 .3 wt.% or less, such as 1 .2 wt.% or less, such as 1 .1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the aforementioned weight percentages may apply to an elastomer used alone as well as a mixture of elastomers.
  • the elastomer may have a mean particle size of 0.01 pm or more, such as 0.05 pm or more, such as 0.1 pm or more, such as 0.12 pm or more, such as 0.14 pm or more, such as 0.15 pm or more, such as 0.2 pm or more.
  • the elastomer may have a mean particle size of 1 pm or less, such as 0.8 pm or less, such as 0.6 pm or less, such as 0.5 pm or less, such as 0.4 pm or less, such as 0.3 pm or less, such as 0.25 pm or less, such as 0.2 pm or less, such as 0.18 pm or less, such as 0.16 pm or less, such as 0.15 pm or less.
  • the mean particle size may be determined using various techniques as known in the art.
  • the elastomer may be functionalized.
  • the terminals of the elastomer may be functionalized.
  • the functional group may include an amine, a hydroxyl, an alkoxy, a sulfonate, a carboxyl, a phosphonate, a halogen, or a thiol.
  • functional group may include a carboxyl to provide a carboxylated elastomer.
  • the carboxyl group may include, but is not limited to, an acrylic acid, a methacrylic acid, a maleic acid, an itaconic acid, etc.
  • the elastomer may have an elongation at break of 100% or more, such as 200% or more, such as 300% or more, such as 500% or more, such as 700% or more, such as 900% or more, such as 1 ,000% or more.
  • the elastomer may have an elongation at break of 2,500% or less, such as 2,000% or less, such as 1 ,800% or less, such as 1 ,500% or less, such as 1 ,300% or less, such as 1 ,100% or less, such as 1 ,000% or less.
  • the elongation at break may be determined according to ASTM D412-16.
  • the elastomer may be presented as a dispersion, such as an aqueous dispersion.
  • the dispersion may include at least 10 wt.%, such as at least 20 wt.%, such as at least 30 wt.%, such as at least 40 wt.%, such as at least 45 wt.%, such as at least 50 wt.% solids based on the entire weight of the dispersion.
  • the dispersion may include 80 wt.% or less, such as 70 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less solids based on the entire weight of the dispersion.
  • the solids content may be determined in accordance with ISO 3251 .
  • One example of a commercially available elastomer is Lipaton® SB 5843 provided by Synthomer®.
  • the joint compound composition may include a siloxane polymer.
  • the siloxane polymer may be a dialkylsiloxane polymer.
  • the alkyl may be a C1-C4 alkyl, such as a C1-C2 alkyl, such as a Ci alkyl (i.e. , methyl).
  • the siloxane polymer may be a dimethylsiloxane polymer (polydimethylsiloxane).
  • the siloxane polymer may be modified. The modification may be a terminal modification or a side chain modification (e.g., to the alkyl, such as the methyl).
  • the modification is a terminal modification. In another embodiment, the modification is a side chain modification. Regardless, the modification may be by using a polyether to provide a polyether siloxane polymer (in other words a dimethicone copolyol).
  • the polyether may be formed from polyethylene glycol, polypropylene glycol, or a mixture thereof. Such polyether may have 2 or more, such as 3 or more, such as 4 or more, such as 5 or more, such as 8 or more, such as 10 or more moles or repeat units. Such polyether may have 30 or less, such as 25 or less, such as 20 or less, such as 18 or less, such as 16 or less, such as 12 or less, such as 10 or less, such as 8 or less moles or repeat units.
  • the modification is a polyethylene glycol to provide a polyoxyethylene modified siloxane polymer, in particular a polyoxyethylene modified polydimethylsiloxane.
  • the siloxane polymer may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.75 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the siloxane polymer may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .25 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may also include a binder.
  • the binder may include an acetate polymer, an acrylic polymer, a polyvinyl alcohol, a cellulose polymer, a starch, etc., or a mixture thereof.
  • the binder may include at least two of an acetate polymer, an acrylic polymer, a polyvinyl alcohol, a cellulose polymer, or a starch.
  • the binder may include at least a mixture of an acetate polymer and a cellulose polymer.
  • the binder may include at least an acetate polymer.
  • the binder may include at least a cellulose polymer.
  • the acetate polymer may include a vinyl acetate, such as an ethylene vinyl acetate.
  • the acetate polymer may be a polyvinyl acetate, a polyethylene vinyl acetate, or a mixture thereof.
  • the acetate polymer may include polyvinyl acetate.
  • the acetate polymer may include polyethylene vinyl acetate.
  • the acetate polymer may be a mixture of two acetate polymers, such as any two of the aforementioned.
  • the acrylic polymer may be any acrylic polymer.
  • the acrylic polymer may be a polyacrylate.
  • the acrylic polymer may be a polyvinyl acrylic polymer.
  • the acrylic polymer may be a polyvinyl acetate acrylate.
  • the acrylic polymer may be a mixture of two acrylic polymers, such as any two of the aforementioned.
  • the cellulose polymer may include a cellulose ether.
  • the cellulose ether may include one wherein the hydroxyl groups are partially or fully replaced by -OR groups, wherein R is a substituted or substituted alkyl.
  • the alkyl may be a Ci-Ce alkyl.
  • the alkyl may be methyl, ethyl, propyl, or a combination thereof. If a substitution is present, the substitution may include a hydroxy or a sulfo substitution.
  • the cellulose ether may be soluble in water at ambient temperature.
  • the cellulose ether may be an alkyl cellulose, a hydroxyalkyl cellulose, or a mixture thereof.
  • the cellulose ether may include, but is not limited to methylcellulose, ethyl cellulose, propyl cellulose, butyl cellulose, hydroxyethyl methylcellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, ethylhydroxyethylcellulose, methylethylhydroxyethylcellulose, methylhydroxyethylcellulose, ethylmethylhydroxypropylcellulose, ethylhydroxyethylcellulose, etc., and mixtures thereof.
  • the cellulose ether may be a hydroxypropyl methylcellulose.
  • the cellulose ether may have a particular degree of substitution (i.e. , the average number of substituted hydroxyl groups per glucose united).
  • the degree of substitution may be 0.1 or more, such as 0.2 or more, such as 0.3 or more, such as 0.5 or more, such as 1 or more, such as 1 .3 or more, such as 1 .5 or more, such as 2 or more.
  • the degree of substitution may be 3 or less, such as 2.8 or less, such as 2.5 or less, such as 2.3 or less, such as 2 or less.
  • the binder may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the binder may be present in an amount of 10 wt.% or less, such as 8 wt.% or less, such as 6 wt.% or less, such as 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .4 wt.% or less, such as 1 .3 wt.% or less, such as 1.2 wt.% or less, such as 1 .1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less, such as 0.3 wt.% or less, such as 0.2 w
  • the binder may be presented as an emulsion.
  • the emulsion may include at least 10 wt.%, such as at least 20 wt.%, such as at least 30 wt.%, such as at least 40 wt.%, such as at least 45 wt.%, such as at least 50 wt.% actives based on the entire weight of the emulsion.
  • the emulsion may include 80 wt.% or less, such as 70 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less actives based on the entire weight of the emulsion.
  • the joint compound composition may also include other additional fillers.
  • these other additional fillers may include perlite, glass, etc.
  • the additional filler may include perlite.
  • the perlite may be unexpanded perlite, expanded perlite, or a mixture thereof.
  • the perlite may include expanded perlite.
  • the additional filler may include a glass.
  • the additional filler such as the perlite
  • the additional filler may be treated. In one embodiment, it may remain untreated. In another embodiment, it may be treated such as to providing a coating.
  • the treatment may be a hydrophobic treatment to provide a hydrophobic filler, such as a hydrophobic perlite. Such hydrophobicity may be obtained by treated the perlite with a surface-active agent.
  • the treatment and coating may be with one or more silanes, siloxanes, silicone coatings, or a mixture thereof. These may include in particular, but are not limited to, dimethyl silicone, dimethyldichlorosilane or polydimethylsiloxane.
  • coatings may also include titanates or zirconates.
  • the coating may be provided in an amount of 0.01 wt.% or more, such as 0.02 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.5 wt.% or more to 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2.5 wt.% or less, such as 2 wt.% or less, such as 1.5 wt.% or less, such as 1 wt.% or less based on the uncoated weight of the filler, such as the perlite.
  • the additional filler may be present in an amount of at least 0.01 wt.%, such as at least 0.05 wt.%, such as at least 0.1 wt.%, such as at least 0.5 wt.%, such as at least 1 wt.%, such as at least 2 wt.%, such as at least 5 wt.%, such as at least 6 wt.%, such as at least 8 wt.%, such as at least 10 wt.% based on the weight of the joint compound composition.
  • the additional filler may be present in an amount of 30 wt.% or less, such as 25 wt.% or less, such as 20 wt.% or less, such as 15 wt.% or less, such as 13 wt.% or less, such as 11 wt.% or less, such as 10 wt.% or less, such as 8 wt.% or less, such as 6 wt.% or less, such as 5 wt.% or less, such as 2 wt.% or less, such as 1 wt.% or less, such as 0.5 wt.% or less, such as 0.1 wt.% or less based on the weight of the joint compound composition.
  • the aforementioned weight percentages may apply to a single additional filler used alone as well as a mixture of additional fillers.
  • the joint compound composition may also include a surfactant.
  • the joint compound composition may also include two surfactants.
  • the surfactant may be cationic, anionic, nonionic, or amphoteric.
  • the surfactant may be anionic.
  • the surfactant may be nonionic.
  • the surfactant may include one that is anionic and another that is nonionic.
  • the surfactant may include a surfactant system.
  • the anionic surfactant may include, but is not limited to, alkyl sulfates, sulfates of ethoxylate alcohols, aryl sulfonates, phosphates of ethoxylated alcohols, sulfosuccinates, sulfates and sulfonates of ethoxylated alkylphenols, and mixtures thereof.
  • the nonionic surfactant may include, but is not limited to, ethoxylated alcohols, ethoxylated alkylphenols, and mixtures thereof.
  • the nonionic surfactant may be one that is known to be environmentally benign and (alkyl phenyl ethoxylate)-free, especially (nonylphenol ethoxylate)-free, examples of which include linear and/or branched alkyl ethoxylates.
  • the cationic surfactant may include, but is not limited to, ethoxylated fatty amines and salts thereof.
  • the surfactant may include one having a polymerizable carbon-carbon double bond.
  • alkylphenol ethoxylates containing alkenyl substituents may include, but are not limited to, alkylphenol ethoxylates containing alkenyl substituents, polyoxyalkylene alkyl ether sulfate salts, salts of poly(oxy-1 ,2-ethanediyl), alpha- sulfo-omega-[1 -(hydroxymethyl)-2-(2-propenyloxy)ethoxy], etc.
  • Additional surfactants may include, but are not limited to, saturated and ethylenically unsaturated sulfonic acids or salts thereof, including, for example, unsaturated hydrocarbonsulfonic acid, such as vinylsulfonic acid, allylsulfonic acid and methallylsulfonic acid, and salts thereof; aromatic hydrocarbon acids, such as, for example, p-styrenesulfonic acid, isopropenylbenzenesulfonic acid and vinyloxybenzenesulfonic acid and salts thereof; sulfoalkyl esters of acrylic acid and methacrylic acid, such as, for example, sulfoethyl methacrylate and sulfopropyl methacrylate and salts thereof, and 2-acrylamido-2- methylpropanesulfonic acid and salts thereof; alkylated diphenyl oxide disulfonates, sodium dodecylbenzenesulfonat.es and dihex
  • the surfactant may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the surfactant may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .4 wt.% or less, such as 1 .3 wt.% or less, such as 1.2 wt.% or less, such as 1 .1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the aforementioned weight percentages may apply to a single surfactant used alone as well as a mixture of surfactants.
  • the joint compound composition may also include a defoamer.
  • the defoamer may include mineral oil, silicone oil, hydrocarbon oil, a polyglycol, a fatty acid derivative, a trialkyl phosphate, etc., or a mixture thereof.
  • the defoamer may include mineral oil (e.g., paraffin oil).
  • the defoamer may include silicone oil.
  • the defoamer may include a mixture of mineral oil and silicone oil.
  • the defoamer may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the defoamer may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .4 wt.% or less, such as 1 .3 wt.% or less, such as 1.2 wt.% or less, such as 1 .1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may also include other additives as generally known in the art. These additives may include, but are not limited to, stabilizers, suspending agents, preservatives, pigments, colorants, flattening agents, LIV absorbers, LIV stabilizers, chemical markers/traceability agents, accelerators, etc.
  • the joint compound composition may include at least one preservative.
  • the preservative may include a biocide.
  • such preservative may include a bactericide, a fungicide, a mildewcide, or a mixture thereof.
  • Such preservatives may include any typically utilized in the art.
  • the biocide may include a mixture of an amine, an azole, and a carbamate.
  • the biocide may include a mixture of a pyrithione, an isothiazolinone, and a carbamate.
  • the preservative may be present in an amount of 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.75 wt.% or more, such as 1 wt.% or more based on the weight of the joint compound composition.
  • the preservative may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .25 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may include latex.
  • latex may be present in the joint compound composition in an amount of about 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more, such as 1 .2 wt.% or more, such as
  • the latex may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1 .4 wt.% or less, such as 1 .3 wt.% or less, such as 1 .2 wt.% or less, such as 1.1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may include sorbitol.
  • sorbitol may be present in the joint compound composition in an amount of about 0.001 wt.% or more, such as 0.01 wt.% or more, such as 0.05 wt.% or more, such as 0.1 wt.% or more, such as 0.2 wt.% or more, such as 0.25 wt.% or more, such as 0.3 wt.% or more, such as 0.4 wt.% or more, such as 0.5 wt.% or more, such as 0.6 wt.% or more, such as 0.7 wt.% or more, such as 0.8 wt.% or more, such as 0.9 wt.% or more, such as 1 wt.% or more, such as 1 .2 wt.% or more, such as 1 .4 wt.% or more, such as 1 .5 wt.% or more, such as 1 .6
  • the sorbitol may be present in an amount of 5 wt.% or less, such as 4 wt.% or less, such as 3 wt.% or less, such as 2 wt.% or less, such as 1 .5 wt.% or less, such as 1.4 wt.% or less, such as 1.3 wt.% or less, such as 1.2 wt.% or less, such as 1.1 wt.% or less, such as 1 wt.% or less, such as 0.9 wt.% or less, such as 0.8 wt.% or less, such as 0.7 wt.% or less, such as 0.6 wt.% or less, such as 0.5 wt.% or less, such as 0.4 wt.% or less based on the weight of the joint compound composition.
  • the joint compound composition may have a particular solids to water ratio.
  • the solids may constitute 25 wt.% or more, such as 30 wt.% or more, such 35 wt.% or more, such as 40 wt.% or more, such as 45 wt.% or more, such as 50 wt.% or more of the joint compound composition.
  • the solids may constitute 80 wt.% or less, such as 75 wt.% or less, such as 70 wt.% or less, such as 65 wt.% or less, such as 60 wt.% or less, such as 55 wt.% or less, such as 50 wt.% or less of the joint compound composition.
  • the joint compound composition may have better flow characteristics and takes less effort to apply.
  • the present joint compound composition may exhibit a relatively low viscosity.
  • the joint compound composition may exhibit a viscosity of 50 poise or less, such as 40 poise or less, such as 30 poise or less, such as 25 poise or less, such as 20 poise or less, such as 15 poise or less, such as 10 poise or less when measured at a temperature of 23°C and according to the method described below at a shear rate of 100 s’ 1 .
  • the viscosity may be 1 poise or more, such as 2 poise or more, such as 3 poise or more, such as 4 poise or more, such as 5 poise or more, such as 6 poise or more, such as 7 poise or more, such as 8 poise or more, such as 9 poise or more, such as 10 poise or more when measured at a temperature of 23°C and according to the method described below at a shear rate of 100 s -1 .
  • the joint compound composition disclosed herein may have a viscosity of about 100 BU to about 1000 BU, where “BU” refers to Brabender units.
  • the joint compound composition disclosed herein may have a viscosity of about 100 BU or more, such as about 200 BU or more, such as about 300 BU or more, such as about 400 BU or more, such as about 500 BU or more, such as about 600 BU or more, such as about 700 BU or more, such as about 800 BU or more, such as about 900 BU or more.
  • the joint compound composition disclosed herein may have a viscosity of about 1000 BU or less, such as about 900 BU or less, such as about 800 BU or less, such as about 700 BU or less, such as about 600 BU or less, such as about 500 BU or less, such as about 400 BU or less, such as about 300 BU or less, such as about 200 BU or less.
  • the joint compound composition as disclosed herein may demonstrate a lower yield stress.
  • the yield stress may be 1 ,500 dynes/cm 2 or less, such as 1 ,300 dynes/cm 2 or less, such as 1 ,100 dynes/cm 2 or less, such as 1 ,000 dynes/cm 2 or less, such as 800 dynes/cm 2 or less, such as 600 dynes/cm 2 or less, such as 500 dynes/cm 2 or less, such as 400 dynes/cm 2 or less when measured at a temperature of 23°C and according to the method described below.
  • the yield stress may be 100 dynes/cm 2 or more, such as 200 dynes/cm 2 or more, such as 300 dynes/cm 2 or more, such as 400 dynes/cm 2 or more, such as 500 dynes/cm 2 or more when measured at a temperature of 23°C and according to the method described below.
  • the lower yield stress generally indicates a lower effort to apply.
  • the present inventors have discovered that, unlike more traditional joint compound compositions, the joint compound composition as disclosed herein has a longer “life.” For instance, the joint compound composition as disclosed herein may be able to sit for a longer period of time without thickening to a degree that would require remixing.
  • the present invention is also directed to a method of making the aforementioned joint compound composition.
  • the method may include a step of combining and mixing any of the aforementioned components.
  • the method may include a step of providing or combining and mixing water, a cementitious filler, and fiber, such as natural fiber.
  • the method may include a step of applying the joint compound composition to a joint between adjacent gypsum wallboards. After allowing the joint compound composition to dry and cure, tape, such as drywall joint tape, may be applied to a portion of the joint compound composition or may be applied over the entirety of the joint compound composition.
  • the joint compound composition as mentioned herein may have application in the building industry.
  • the joint compound composition may be available as a “ready-mix” formulation (ready to use without needing additional water).
  • the joint compound composition can be utilized with construction panels such as gypsum wallboards.
  • the joint compound compositions can be applied to gaps (or joints) between adjacent, affixed gypsum wallboards, whether applied to a gap itself or joint tape applied over the gap.
  • the joint compound composition can be applied to any cracks or screw holes and/or nail holes used to affix the gypsum wallboards.
  • Such application of the joint compound composition can provide a smooth, visually appealing surface.
  • the joint compound composition is generally regarded as a drying-type joint compound composition.
  • the water evaporates and the composition dries to form a relatively hard cementitious material. Once hardened, the remaining material may be sanded to provide a smoother surface that may be later manipulated (e.g., painted).
  • a joint compound composition was prepared according to the formulation provided below in Table 1 .

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Inorganic Chemistry (AREA)
  • Sealing Material Composition (AREA)

Abstract

La présente divulgation concerne une composition de composé à joint. La composition de composé à joint comprend de l'eau, une charge cimentaire et de la fibre. La composition de composé à joint de la présente divulgation présente une force et une résistance à la fissuration améliorées. La présente divulgation concerne également un procédé de fabrication d'une composition de composé à joint. Le procédé comprend les étapes consistant à combiner et à mélanger de l'eau, une charge cimentaire et de la fibre.
PCT/US2023/035885 2022-10-28 2023-10-25 Composition de composé à joint améliorée par des fibres WO2024091548A1 (fr)

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US202263420155P 2022-10-28 2022-10-28
US63/420,155 2022-10-28

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WO2024091548A1 true WO2024091548A1 (fr) 2024-05-02

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5336318A (en) * 1990-09-17 1994-08-09 United States Gypsum Company Clay-free, asbestos-free and glass microbubble-free drying type joint compounds
US5746822A (en) * 1994-05-12 1998-05-05 United States Gypsum Company Ready-mixed setting type joint compound
US20170081245A1 (en) * 2014-03-14 2017-03-23 Lamberti Spa Joint compounds
US20210147703A1 (en) * 2019-11-14 2021-05-20 National Gypsum Properties, Llc Lightweight Joint Compound Composition
US20210230067A1 (en) * 2020-01-28 2021-07-29 United States Gypsum Company Setting type joint compound compositions with reduced plaster

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5336318A (en) * 1990-09-17 1994-08-09 United States Gypsum Company Clay-free, asbestos-free and glass microbubble-free drying type joint compounds
US5746822A (en) * 1994-05-12 1998-05-05 United States Gypsum Company Ready-mixed setting type joint compound
US20170081245A1 (en) * 2014-03-14 2017-03-23 Lamberti Spa Joint compounds
US20210147703A1 (en) * 2019-11-14 2021-05-20 National Gypsum Properties, Llc Lightweight Joint Compound Composition
US20210230067A1 (en) * 2020-01-28 2021-07-29 United States Gypsum Company Setting type joint compound compositions with reduced plaster

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