WO2024097659A2 - Compositions de composés pour joints de type à prise rapide sans perlite - Google Patents

Compositions de composés pour joints de type à prise rapide sans perlite Download PDF

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Publication number
WO2024097659A2
WO2024097659A2 PCT/US2023/078200 US2023078200W WO2024097659A2 WO 2024097659 A2 WO2024097659 A2 WO 2024097659A2 US 2023078200 W US2023078200 W US 2023078200W WO 2024097659 A2 WO2024097659 A2 WO 2024097659A2
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WIPO (PCT)
Prior art keywords
composition
dry
weight
water
perlite
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PCT/US2023/078200
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English (en)
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WO2024097659A3 (fr
Inventor
Alexander J. Donovan
Naveen Punati
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United States Gypsum Company
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Priority claimed from US18/205,074 external-priority patent/US20240150244A1/en
Application filed by United States Gypsum Company filed Critical United States Gypsum Company
Publication of WO2024097659A2 publication Critical patent/WO2024097659A2/fr
Publication of WO2024097659A3 publication Critical patent/WO2024097659A3/fr

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Classifications

    • 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
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
    • C04B28/146—Calcium sulfate hemi-hydrate with a specific crystal form alpha-hemihydrate
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672—Pointing or jointing materials
    • C04B2111/00689—Pointing or jointing materials of the setting type
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material

Definitions

  • compositions for perlite-free, lightweight setting-type joint compounds useful as all-purpose joint compounds in interior and exterior finishings including in filling and finishing seams between adjacent interior gypsum panels or exterior gypsum panels, and/or for wall patch and repair projects.
  • Gypsum wallboards which can be also referred to as drywall are commonly used in construction of walls and ceilings in commercial and residential buildings. Often, a wall or ceiling is assembled by attaching wallboards one by one to a supporting frame (studs). A seam between two adjacent attached wallboards or other gypsum panels is called a joint. In order to strengthen the wall assembly and create a wall with a monolithic and even surface without gaps, the joints are filled with an adhesive compound, called a joint compound. Finishing a seam (joint) may require several coats of a joint compound, depending on a shrinkage rate of the joint compound. After the applied joint compound sets, it is often sanded before the wall can be coated with a primer and/or painted and/or decorated.
  • Examples of wall assemblies and joint compounds known in the art include those disclosed in U.S. Patents 4,454,267, 6.545,066, 8,931,230 and 9,169,426, the entire disclosures of which are incorporated herein by reference.
  • Conventional joint compounds include drying-type joint compounds and setting-type joint compounds, including as described in U.S. Patents 4,454,267, 5,746,822, 6,545,066, and 10,669,215, the disclosures of which are herein incorporated in their entirety. Drying-type joint compounds harden through the evaporation of water, while setting-type joint compounds harden by curing because they comprise calcined gypsum which hydrates into a gypsum matrix after being mixed with water. Accordingly, joint compounds formulated with calcined gypsum may be referred in this disclosure as setting-type joint compounds.
  • joint compounds which comprise perlite are commonly used.
  • Some of the technical advantages for joint compounds that comprise perlite include light weight, good bond to a substrate and sanding ease.
  • perlite is a naturally occurring mineral and it is important to preserve natural resources.
  • a perlite-free, lightweight setting-type joint compound composition comprising calcined gypsum and a foaming agent.
  • this disclosure provides a composition for perlite-free, lightweight setting-type joint compound, wherein the composition comprises: calcium sulfate hemihydrate with a dry density of less than 50 lb/ft 3 and water consistency of at least 50 cc of water per 100 grams of calcium sulfate hemihydrate; a foaming agent having a hydrophilic-lipophilic balance (HLB) value of at least 10, the foaming agent preferably comprising an alkylbcnzcnc sulfonic acid having a linear alkyl chain containing 8 to 14 carbons and/or a salt thereof; optionally, a co- surfactant, wherein the co-surfactant includes a betaine, alkanolamide, alkylpolyglucoside, alkyl ethoxylate, or any combination thereof; a rheology modifier including one or more of the following: modified cellulose, starch, and/or attapulgite clay; and wherein the composition does not comprise perlite
  • Embodiments for the composition include those, wherein calcium sulfate hemihydrate includes alpha calcium sulfate hemihydrate in an amount ranging from about 50 wt% to about 95 wt% by weight of the dry-powder composition.
  • alpha calcium sulfate hemihydrate may be obtained by autoclaving gypsum in a saturated steam atmospheric pressure, and wherein alpha calcium sulfate hcmihydratc has a dry density of about 45 lb/ft 3 and water consistency of about 60 cc per 100 grams of alpha calcium sulfate hemihydrate.
  • the composition may comprise from about 0.01 wt% to about 0.5 wt% of the foaming agent by weight of the dry-powder composition.
  • the composition may comprise dodecyl benzene sulfonic acid or any salt thereof.
  • the composition may comprise from about 0.1 wt% to about 1.0 wt% of the co-surfactant by weight of the dry-powder composition.
  • Preferred embodiments include compositions which comprise cocoamidopropyl betaine.
  • compositions may comprise modified cellulose and/or starch in an amount from about 0.1 wt% to about 2 wt% by weight of dry-powder composition.
  • compositions may comprise carboxymethyl cellulose, hydroxypropyl methyl cellulose, xanthan gum, methyl hydroxyethyl cellulose, attapulgite clay, or any combination thereof.
  • compositions may comprise one or more of the following: mica, talc, calcium carbonate, and/or any combination thereof.
  • compositions according to this disclosure include those which comprise water in an amount ranging from about 40 cc to 70 cc of water per 100 grams of dry-powder composition.
  • the compositions may further comprise a binder which may include one or more of the following: starch, polyvinyl alcohol, polyvinyl acetate, styrenebutadiene, ethylenevinyl acetate co-polymer, vinyl-acrylic co-polymer, and/or any combination thereof.
  • compositions include ready-mixed compositions which further comprise water and one or more of phosphate compounds.
  • compositions according to this disclosure may further comprise one or more of foaming adjuvants and/or foam stabilizers, or any combination thereof.
  • compositions according to this disclosure may further comprise one or more of the following: diethylenetriamine pentaacetic acid, tartaric acid, citric acid, maleic acid or salts thereof, or any combination thereof.
  • compositions according to this disclosure may further include one or more set accelerators enclosed in a separate container.
  • the composition may comprise: about 60 wt% to about 90 wt% of alpha calcium sulfate hemihydrate having a dry density in the range from about 30 to about 50 lb/ft 3 and having a water consistency of at least about 50 cc of water per 100 grams of calcined gypsum; about 2 wt% to about 30 wt% of calcium carbonate, by weight of dry-powder composition; about 0.01wt% to about 0.5 wt% of sodium dodecyl benzene sulfonate, by weight of dry-powder composition; optionally, about 0.1 wt% to about 1 wt% of cocamidopropyl betaine, by weight dry-powder composition; optionally, about 1 wt% to about 10 wt% mica and/or talc, by weight of dry-
  • this disclosure relates to a method for making perlite-free, lightweight setting-type joint compound according to this disclosure, the method comprising: a) mixing dry components into a first mixture; b) mixing liquid components and water into a second mixture, and c) supplying the second mixture in a separate container or mixing the first mixture and the second mixture in order to form a setting type joint compound.
  • this disclosure relates to a method for finishing a seam between two adjacent gypsum panels attached to a stud, the method comprising filling the seam with the composition according to this disclosure, and/or applying the composition according to this disclosure as a top-coat.
  • this disclosure relates to wall assemblies comprising one or more compositions according to this disclosure
  • this disclosure relates to a method for decreasing a wet density of a joint compound which does not comprise perlite, the method comprising: mixing calcium sulfate hemihydrate having a dry density of less than 50 lb/ft 3 and water consistency of at least 50 cc of water per 100 grams of calcium sulfate hemihydrate with one or more surfactants having a hydrophilic-lipophilic balance (HLB) value of at least 10, and producing a joint compound paste weighing about 10 Ibs/gal to about 12 Ibs/gal when mixed with water.
  • HLB hydrophilic-lipophilic balance
  • Fig. 1A is a schematic depicting a prior art joint compound with perlite, having a low wet density. This figure is not drawn to scale.
  • Fig. IB is a schematic depicting a prior art joint compound with no perlite, having a high wet density. This figure is not drawn to scale.
  • Fig. 1C is a schematic depicting one embodiment of the inventive joint compound comprising one or more surfactants preferably with foaming aids (not shown) and having foam bubbles which replace hollow perlite microspheres of prior art and provide the same lightweight properties, including low wet density, as perlite. This figure is not drawn to scale.
  • Fig. 2 is a matrix reporting properties of the perlite-free, lightweight setting-type joint compounds of this disclosure in comparison to a control joint compound which comprises perlite.
  • calcined gypsum may be used interchangeably with any of the following terms: calcium sulfate hemihydrate, stucco, calcium sulfate semi-hydrate, plaster, calcium sulfate half-hydrate or plaster of Paris.
  • the term “gypsum” may refer to any of the following: naturally mined gypsum (ore), landplaster and/or synthetic gypsum.
  • the term “gypsum” may be used interchangeably with the term “calcium sulfate dihydrate.”
  • the “synthetic gypsum” can be also referred to as “chemical gypsum.”
  • the term “wallboard” means a gypsum panel having a gypsum matrix core sandwiched between two paper cover sheets.
  • the term “wallboard” may be used interchangeable with any of the following terms: gypsum panel, gypsum wallboard, drywall, gypsum board or board.
  • the term “about” means a range of plus/minus 5% of the stated value.
  • “about 100” means 100+5 and “about 200” means 200+10.
  • wt% means percentage by weight.
  • “calcination” means a process by which gypsum (CaSO4-2H 2 O) is dehydrated into calcined gypsum (CaSO 4 - 1/2H 2 O). The process includes heating gypsum to evaporate crystalline water. Calcined gypsum can be produced in different crystalline forms such as alpha calcium sulfate hemihydrate and beta calcium sulfate hemihydrate. All crystalline forms and any mixtures thereof are suitable for compositions according to this disclosure.
  • room temperature means a temperature in the range 68 to 77 °F (20 to 25 °C).
  • ASTM tests refer to tests published by ASTM International, formally known as American Society for Testing and Materials. Detailed test protocols for ASTM tests are available from the ASTM International website.
  • a gypsum slurry means a water-based gypsum slurry or paste in which calcined gypsum is mixed with at least water, and preferably also with one or more additives.
  • composition may be used interchangeably with the term “composition” and/or “mixture.”
  • some compositions may be referred to as “dry” composition or mixture if no water was added to the composition.
  • dry means that no water or other liquid was added to the composition or mixture.
  • a dry composition or dry mixture may have some moisture content.
  • a dry mixture may have a moisture content of about 1 wt% or less, about 0.05 wt% or less, or about 0 wt%. It should be noted that water molecules bound with stucco are not being considered as “free-water.”
  • lightweight joint compound means a water-based joint compound having a weight of less than 12 pounds per one gallon.
  • DBSA dodecyl benzene sulfonic acid
  • CAPB cocamidopropyl betaine
  • this disclosure relates to compositions for a setting-type joint compound, including ready-mixed setting type joint compounds.
  • Preferred embodiments include a perlite- free, lightweight setting-type joint compound composition comprising calcined gypsum and a foaming agent.
  • the perlite-free, lightweight setting-type joint compounds according to this disclosure have sanding ease, dry density (package weight), wet density and substrate-surface coverage during application to a substrate substantially equivalent to conventional perlite-containing, lightweight setting-type joint compounds.
  • expanded perlite may produce airborne dust with potentially respirable crystalline silica (RCS).
  • joint compounds according to this disclosure do not comprise perlite, yet another technical advantage of the present perlite-free, lightweight setting-type joint compounds avoiding the RCS safety concern for operators at the manufacturing plant and users in the field who sand a surface to which a joint compound has been applied.
  • the joint compounds compositions according to this disclosure comprise (1) a low dry density calcined gypsum; and (2) a foaming agent. These joint compounds can be prepared in drypowder form which is mixed with water by a user or as a ready-mixed paste which is premixed with water and stored as a ready-to-use paste.
  • the joint compounds according to this disclosure are suitable for many different applications, including for use with interior gypsum panels and exterior gypsum ceiling boards.
  • the joint compounds are lightweight, meaning that the joint compounds have a weight of less than 12 Ib/gal when mixed with water. Despite not comprising perlite, the joint compounds are easy to sand, as shown by a comparative analysis in this disclosure.
  • joint compounds according to this disclosure have acceptable bond to paper tape and low shrinkage, as shown by a comparative analysis in this disclosure.
  • inventive pcrlitc-frcc, lightweight setting-type joint compound with a combination of several components, as described below.
  • a first necessary component in the perlite-free, lightweight setting-type joint compounds according to this disclosure is calcined gypsum (stucco, plaster, calcium sulfate hemihydrate, calcium sulfate semi-hydrate, calcium sulfate half-hydrate or plaster of Paris).
  • Gypsum can be sourced from mines in the dihydrate form (CaSO4-2H2O), or in form of synthetic gypsum from flue gas desulfurization (FGD).
  • Mined gypsum (landplaster) is composed mostly of calcium sulfate dihydrate, preferably 80% or more by weight calcium sulfate dihydrate and more preferably, about 90% to 95% by weight calcium sulfate dihydrate, and may also contain impurities and inert materials which are typically found in natural gypsum ore. Gypsum is then calcined in order to drive off some water, which produces calcium sulfate hemihydrate. Depending on various factors, including the source of gypsum and also a method by which gypsum is calcined, calcined gypsum can be produced in alpha-crystal form or beta-crystal form.
  • Alpha crystals are less acicular than beta crystals.
  • alpha-calcined gypsum differs in its water demand from betacalcined gypsum, with alpha-calcined gypsum requiring less water for forming a flowable aqueous gypsum slurry.
  • Suitable calcined gypsum may contain alpha calcium sulfate hemi-hydrate, beta calcium sulfate hemi-hydrate, calcined synthetic gypsum, or any mixtures thereof.
  • the perlite-free, lightweight setting-type joint compound according to this disclosure may comprise calcined gypsum in an amount ranging from about 50 wt% to about 95 wt%, preferably from about 60 wt% to about 90 wt%, and most preferably from about 60 wt% to about 75 wt% by weight of dry-powder composition.
  • Preferred calcined gypsum includes that which has a high-water demand and low density.
  • alpha calcium sulfate hemi-hydrate conventionally has a low water demand and a higher density. In view of this, it is unexpected that preferred alpha calcium sulfate hemihydrate in formulations according to this disclosure has a high-water demand (consistency) and low density.
  • Preferred calcined gypsum according to this disclosure may include low-density and high-consistency calcium sulfate hemihydrate, and more preferably, beta calcium sulfate hemihydrate or alpha calcium sulfate hemihydrate which was produced by calcining gypsum under increased saturated steam pressure, e.g. by autoclaving in a saturated steam atmospheric pressure ranging from about 13 to about 60 psi.
  • the resulting particle size distribution in alpha calcium sulfate hemihydrate has a higher surfacc-arca-to-volumc ratio, contributing to both a higher normal pour consistency and significantly lower dry loose bulk density.
  • a joint compound composition can be formulated in the absence of perlite that matches the dry density (package weight) requirements, but has wet density and other properties more similar to conventional weight joint compounds.
  • calcined gypsum is a high-consistency alpha and/or beta calcium sulfate hemihydrate with a dry (without water being added) loose (without compaction) bulk density in the range from about 30 to about 50 pounds per cubic foot (lb/ft 3 ) and more preferably, in the range from about 40 to about 50 lb/ft 3 .
  • dry loose bulk density means a density of less or equal to 50 lb/ft 3 wherein “dry” means no water added, “loose” means without compaction and “bulk” means powder in general and not per individual particle.
  • “low dry loose bulk density” may be simply referred to as “low density.”
  • “high-consistency” means a water demand of at least 50 cc or more, e.g., 52, 53, 54, 55, 56, 57, 58, 59, or 60 cc of water per 100 grams of calcined gypsum.
  • “high-consistency” ranges include, but are not limited to, from about 50 cc to about 70 cc, and more preferably from about 50 cc to about 65 cc, e.g., from about 50 to about 52, 53, 54, 55, 56, 57, 58, 59 or 60 cc of water per 100 grams of calcined gypsum.
  • water demand means the amount of water needed for producing a gypsum slurry which flows and is pourable.
  • the water demand may be expressed as a volume of water in cc (or ml) per 100 grams of calcined gypsum.
  • WSR water- to- stucco ratio
  • a water demand for a gypsum slurry can be measured in a slump test which can be conducted essentially as described in U.S. patent 7,504,165, herein incorporated by reference.
  • the setting-type joint compounds according to this disclosure may be formulated with calcined gypsum which is a high-consistency alpha or beta calcium sulfate hemihydrate, or any mixture thereof, with a dry loose bulk density of about 45 pounds per cubic foot (lb/ft 3 ) and a normal pour consistency water demand of about 60 cubic centimeters (cc) of water per 100 grams of calcined gypsum.
  • calcined gypsum which is a high-consistency alpha or beta calcium sulfate hemihydrate, or any mixture thereof
  • a dry loose bulk density of about 45 pounds per cubic foot (lb/ft 3 ) and a normal pour consistency water demand of about 60 cubic centimeters (cc) of water per 100 grams of calcined gypsum.
  • calcined gypsum in addition to or instead of alpha calcium sulfate hemihydrate may comprise beta stucco with a low density and a high-water consistency such as for example, as continuous kettle stucco (CKS) produced by continuous calcining of gypsum in a kettle.
  • the kettle contains a fluidized bed.
  • continuous calcining in a kettle is conducted at a temperature in the range from about 250°F to about 600°F. More preferably, continuous calcining in a kettle can be conducted at a temperature in the range from 275°F to 356°F (135-180°C).
  • foaming agent Another component which is necessary in combination with a low-density calcined gypsum is a foaming agent. It has been unexpectedly found that certain foaming agents may be used instead of perlite, in order to improve sanding ease, decrease the wet density of the composition and improve distribution and adhesion of the composition to a substrate.
  • the foaming agent in certain embodiments is a foaming surfactant.
  • the foaming surfactant may be preferably an anionic surfactant, a nonionic surfactant, a cationic surfactant, or any combination thereof.
  • the compositions of this disclosure may comprise at least one anionic surfactant, preferably having a liner alkyl chain containing between 8 and 14 carbons.
  • Suitable anionic surfactants include, but are not limited to, those having the hydrophilic- lipophilic balance (HLB) of at least 10 or higher, e.g., having the HLB value that falls within the range from 10 to 40, 10 to 30, or 10 to 20.
  • HLB hydrophilic- lipophilic balance
  • hydrophilic-lipophilic balance (HLB) value is determined as follows.
  • a Surfactant is a molecule composed of hydrophilic and lipophilic groups.
  • An anionic surfactant is a surfactant that contains one or more anionic hydrophilic groups.
  • the HLB value can be calculated according to the following equation: molecular weight of the hydrophilic end of the molecule multiplied by 20 and then divided by the total molecular weight of the surfactant, as was described in Stavroudis 2009 (WAAC Newsletter, Vol 31, No. 1) and as was originally described in Griffin 1949 “Classification of surface-active agents by HLB.” Surfactants having the HLB value greater than 10 exhibit hydrophilic properties.
  • Preferred foaming agents may include anionic surfactants which are alkylbenzene sulfonates having a linear alkyl chain containing between 8 and 14 carbons, preferably between 10 and 12 carbons, or any salt thereof.
  • the surfactants may be preferably used in their powder form, e.g., as a sodium salt.
  • the compositions of this disclosure may comprise from about 0.01 wt% to about 0.5 wt%, preferably from about 0.01 wt% to about 0.1 wt%, of the anionic surfactant by weight of dry-powder composition.
  • Particularly preferred anionic surfactants include dodecyl benzene sulfonic acid (“DDB SA,” 2-dodecylbenzenesulfonic acid having PubChem CID number 25457) or any water- soluble salt thereof (sodium, potassium, magnesium, ammonium, etc.) and in particular, sodium dodecyl benzene sulfonate which is commercially available in the powder form.
  • DDB SA dodecyl benzene sulfonic acid
  • PubChem CID number 25457 2-dodecylbenzenesulfonic acid having PubChem CID number 25457
  • any water- soluble salt thereof sodium, potassium, magnesium, ammonium, etc.
  • sodium dodecyl benzene sulfonate which is commercially available in the powder form.
  • a composition for the perlite-free, lightweight setting-type joint compound according to this disclosure may further comprise one or more co- surfactants which may be used in order to increase foaming and improve foam stability.
  • co-surfactants may include betaines, alkanolamides, alkylpolyglucosides, and/or alkyl ethoxylates.
  • Particularly preferred betaine co- surfactants include those disclosed in U.S. Patent Publication 2016/0031761.
  • a co-surfactant may be used in any amount ranging from about 0.1 wt% to about 1.0 wt%, and preferably, from about 0.1 wt% to about 0.5 wt% of the co-surfactant by weight of dry-powder composition.
  • One particularly preferred betaine includes cocoamidopropyl betaine (CAPB) available from Stepan Company under the trademark AMPHOSOL CG-50.
  • prior art joint compounds (10 or 20) include those that comprise perlite microspheres (14) incorporated in hydrating gypsum matrix (12).
  • Joint compounds (10) which comprise perlite microspheres (14) have low wet density when mixed with water, while prior art joint compounds (20) without perlite have a high wet density.
  • an inventive joint compound according to this disclosure generally (30), when mixed with water produces microfoam bubbles, wherein the air-joint compound interface is stabilized by the presence of the surfactants and co- surfactants (16) which intermix with hydrating gypsum matrix (12). It was unexpectedly found that the microfoam bubbles (16) are stable during joint compound working time and produce a low wet density joint compound even as no perlite is used in these compounds.
  • microfoam bubble means a bubble of air entrained in the joint compound matrix with at least one dimension approximately on the micron scale.
  • the interface between the joint compound phase and the air bubble is stabilized by the presence of the foaming agents, i.e., a saturated layer of surfactants, co-surfactants, and/or adjuvants.
  • a composition for the perlite-free, lightweight setting-type joint compound according to this disclosure may further comprise one or more rheology modifiers which may be used in small amounts, e.g., from about 0.1 wt% to about 10 wt%, and more preferably from about 0.1 wt% to about 1 wt%, by weight of dry-powder composition.
  • a composition for the perlite-free, lightweight setting-type joint compound may further comprise one or more foaming adjuvants.
  • foaming adjuvants may include myristic acid, stearic acid, salts of alkyl fatty acid carboxylates (e.g., sodium, potassium), or any combination thereof.
  • the foaming adjuvants may be used in small amounts, e.g., from 0.01 to 1 wt%, by weight of dry-powder composition.
  • a composition for the perlite-free, lightweight setting-type joint compound may further comprise or more foam stabilizers which act to extend the life of the microfoam bubbles in the presence of surfactants and/or co-surfactants. These foam stabilizers also function as rheology modifiers. Suitable microfoam bubble stabilizers include gums, e.g., xanthan gum, gellan gum, and guar gum, and modified celluloses, e.g., hydroxyethyl cellulose (HEC). Foam stabilizers may be used in amounts from 0.01wt% to 2wt%, and preferably 0.05wt% to 0.5wt%, by weight of drypowder composition.
  • foam stabilizers which act to extend the life of the microfoam bubbles in the presence of surfactants and/or co-surfactants. These foam stabilizers also function as rheology modifiers. Suitable microfoam bubble stabilizers include gums, e.g., xanthan gum, gellan
  • One necessary rheology modifier is a clay having gelling and rheological properties for thickening and stabilizing a gypsum composition when mixed with water.
  • a particularly preferred clay may be attapulgite which contains hydrous magnesium aluminum silicate, although other clays, such as for example, as bentonite, sepiolite, and/or kaolinite may be also used either instead or in addition to attapulgite.
  • the clay may be used in any amount sufficient to improve the gelling and rheological properties of the compositions according to this disclosure.
  • the clay, preferably the attapulgite clay may be used in an amount from about 2 wt% to about 10 wt% by weight of dry-powder composition.
  • compositions according to this disclosure may further comprise one or more starches, preferably, pregelatinized and/or modified starches, preferably a pregelatinized wheat, corn and/or potato starch, as a second rheological modifier which may be used in combination with the gelling clay.
  • the one or more starches may be used in any amount sufficient to improve gelling properties of the joint compounds according to this disclosure.
  • the one or more starches may be used in an amount from about 0.1 wt% to about 2 wt% by weight of dry-powder composition.
  • the one or more starches may be pregelatinized.
  • the one or more starches may he modified in order to improve their properties as a thickener, waterretention aid, and their solubility in cold water without heating.
  • Preferred modifications may include pre-gelatinization and/or treating the starch with an inorganic acid and/or carboxymethylating it in order to decrease its viscosity and/or improve its adhesive properties.
  • One or more rheology modifiers may further include modified cellulose, in particular hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), methyl cellulose, hydroxyethyl cellulose, hydroxyethyl methylcellulose (HEMC), hydroxyethyl cellulose, and/or carboxymethylcellulose.
  • modified cellulose in particular hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), methyl cellulose, hydroxyethyl cellulose, hydroxyethyl methylcellulose (HEMC), hydroxyethyl cellulose, and/or carboxymethylcellulose.
  • Particularly preferred rheology modifiers may include carboxymethyl cellulose, hydroxypropyl methyl cellulose, methyl hydroxyethyl cellulose, or any combination thereof.
  • the one or more modified cellulose compounds may be used in combination with the clay and starch rheological modifiers.
  • the compositions may comprise one or more modified cellulose compounds in an amount from about
  • cellulosic rheology modifiers may be used as a dry powder or as a solution. If used as a solution, the cellulosic rheology modifier may have a Brookfield viscosity in the range from about 30,000 cps to about 65,000 cps at room temperature.
  • One particularly preferred rheological modifier includes F-type hydroxypropyl methyl cellulose with a 60,000 cps Brookfield viscosity (2% solution) which can be preferably used at about 0.3 wt% by weight of the dry-powder composition.
  • Suitable rheological modifiers may include gums and in particular, xanthan gum, which is a polysaccharide, that can be used in addition to or instead of modified cellulose. If present, xanthan gum may be used in the same amount as modified cellulose, e.g., in an amount from about 0.01 wt% to about 2 wt% by weight of dry-powder composition.
  • the joint compound according to this disclosure does not comprise perelite which is a naturally occurring inorganic mineral known to be a hydrated natural glass composed of silicon, aluminum, and oxygen and containing occluded water.
  • perelite which is a naturally occurring inorganic mineral known to be a hydrated natural glass composed of silicon, aluminum, and oxygen and containing occluded water.
  • the joint compound composition of this disclosure may optionally include fillers.
  • any of the following fillers may be used either alone or in combination with other fillers: mica, talc, clays, in particular kaolinite, sericite, calcium carbonate which can be sourced as calcite, limestone and/or dolomitic limestone, calcium oxide which can sourced as lime which can be produced by roasting limestone, glass microsphcrcs, pyrophyllite, diatomaceous earth, vermiculite, fly ash, or any combination thereof.
  • the joint compound compositions may comprise calcium carbonate, preferably calcium carbonate which can be sourced as calcite, limestone and/or dolomitic limestone, may be used in an amount from about 2 wt% to about 30 wt%, and more preferably from about 3 wt% to about 25 wt% by weight of dry-powder composition.
  • the other fillers e.g., mica and/or talc may be used in addition to or instead of calcium carbonate. These fillers can be also used in an amount from about 2 wt% to about 30 wt%, and more preferably from about 3 wt% to about 25 wt%.
  • the compositions may comprise calcium carbonate in an amount from about 2 wt% to about 30 wt%, and more preferably from about 3 wt% to about 25 wt% by weight of dry-powder composition and mica and/or talc in an amount from about 1 wt% to about 10 wt% by weight of dry-powder composition.
  • Calcium oxide (lime) may be further added in small amounts, e.g., from about 0.1 wt% to about 1 wt% by weight of dry-powder composition.
  • joint compounds according to this disclosure may comprise one or more binders.
  • Suitable binders include, but are not limited to polyvinyl alcohol, starch, polyvinyl acetate, styrenebutadiene, ethylenevinyl acetate co-polymer, vinyl-acrylic co-polymer, other acrylic polymers, and/or any combination thereof.
  • Suitable starch binders may comprise one or more of the following: wheat starch, com starch, potato starch or any mixture thereof.
  • the starch may be pregelatinized or otherwise modified, e.g., alkylated or treated with an acid. Any of these binders either alone or in combination with other binders may be used in an amount from about 0.1 wt% to about 10 wt% by weight of dry-powder composition.
  • the joint compound compositions according to this disclosure may further comprise other additives.
  • additives include phosphate compounds, set accelerators, set retarders, bactericides, fungicides, pH adjusters, setting-reaction indicators, coloring agents and/or humectants, among others.
  • compositions for joint compounds according to this disclosure may include drypowder compositions as well as ready-mixed joint compounds which are premixed with water during manufacturing and provided to users as a premixed paste.
  • ready-mixed compositions are formulated as a paste which comprises water, preferably in an amount from about 40 wt% to 60 wt% by weight of dry-powder composition.
  • Joint compounds according to this disclosure may include one or more phosphate compounds useful for preventing a premature setting reaction in a ready-mixed joint compound during storage, as described in U.S. Patent 5.746,822 and U.S. Patent 10,669,215, the entire disclosures of both patents are herein incorporated by reference in their entirety.
  • Suitable phosphate compounds include cyclic polyphosphates, condensed phosphoric acids, and monobasic salts or monovalent ions of orthophosphates.
  • Particularly preferred phosphate compounds include, but are not limited to, trimetaphosphate salts and tetrametaphosphate salts.
  • Particularly preferred phosphate compounds include sodium trimetaphosphate (“STMP”), potassium trimetaphosphate, ammonium trimetaphosphate, sodium hexametaphosphate, tetrapotassium tripolyphosphate, ammonium polyphosphate, aluminum trimetaphosphate or any combination thereof.
  • STMP sodium trimetaphosphate
  • potassium trimetaphosphate potassium trimetaphosphate
  • ammonium trimetaphosphate sodium hexametaphosphate
  • tetrapotassium tripolyphosphate ammonium polyphosphate
  • aluminum trimetaphosphate or any combination thereof As reported in U.S.
  • Patent 9,174,881 zinc hexametaphosphate, potassium tripolyphosphate, tetra sodium pyrophosphate, sodium tripolyphosphate, monoammonium phosphate and monobasic potassium phosphate may be particularly suitable for ready-mixed joint compounds.
  • the joint compounds according to this disclosure may comprise from about 0.05 wt% to about 10 wt% of one or more phosphate compounds by weight of calcined gypsum, preferably from about 0.1 wt% to about 5 wt% of one or more phosphate compound by weight of dry-powder composition.
  • Joint compounds according to this disclosure may further comprise one or more of set retarding agents which may be used in order to delay a hydration reaction of calcined gypsum and for increasing a workable time of the joint compound during which it can be applied to a substrate.
  • set retarding agents may include, but are not limited to, commercially available proteinaceous retarders, diethylenetriamine pentaacetic acid (DTP A), tartaric acid, citric acid, maleic acid or salts thereof, including in particular sodium citrate and/or potassium bitartrate (cream of tartar), or any combination thereof.
  • a set retarding agent can be used in a small amount, for example in an amount in the range from about 0.01% to about 1.5% by weight of calcined gypsum, preferably in an amount in the range from about 0.05% to about 0.5% by weight of calcined gypsum.
  • the joint compound compositions according to this disclosure may include one or more set accelerators which can be supplied in a separate container, as described for example in U.S. Patent 9,174,881, and then mixed with the joint compound composition just prior to its use. Suitable set accelerators include those disclosed in U.S. Patents 5,746,822, 9,174,881 and 10,669,215.
  • Particularly preferred set accelerators may include zinc sulfate, alum, aluminum sulfate, a double sulfate of potassium and aluminum, a double sulfate of aluminum and ammonia, a combination of zinc sulfate and iron sulfate, a combination of zinc sulfate and aluminum sulfate, a combination of zinc sulfate and iron oxide, calcium sulfate, calcium sulfate dihydrate, or any combination thereof.
  • Preferred set accelerators also include climate stabilized accelerator (CSA) which may contain about 95% of calcium sulfate dihydrate co-ground with 5% sugar and then heat processed, as was described in U.S. Patent 3,573,947.
  • CSA climate stabilized accelerator
  • Other suitable accelerators include “HRA” which comprises calcium sulfate dihydrate freshly ground with sugar at a ratio of about 5 to about 25 pounds of sugar per 100 pounds of calcium sulfate dihydrate, as described in U.S. patent 2,078,199.
  • Other accelerators for controlling a setting reaction may include wet gypsum accelerator (WGA) as described in U.S. Patent 6,409,825. Any of these set accelerators either alone or in any combination may be used in any amount suitable for controlling the rate of calcined gypsum hydration.
  • a total amount of the set accelerator to be used depends on the set accelerator. In some embodiments, from about 0.01 wt% to about 2 wt% of a set accelerator by weight of dry- powder composition may be included.
  • the joint compound compositions according to this disclosure preferably have a basic pH of at least 7.5, more preferably at least 8.0 or higher.
  • various basic compounds can be used, including, but not limited to, sodium hydroxide, ammonia, potassium hydroxide, triethylamine (TEA) or 2-amino-2-methyl-l propanol (AMP), which can be used in small amounts, e.g., from about 0.1 wt% to about 1 wt% by weight of dry-powder composition.
  • the joint compound compositions according to this disclosure may comprise one or more humectants.
  • Particularly preferred humectants may include, but are not limited to, glycerol, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, di-propylene glycol, and/or tri-propylene glycol, or any combination thereof.
  • the humectant can be used in a small amount, e.g., from about 0.01 wt% to about 5 wt%, and more preferably from about 0.1 wt% to about 5 wt%, by weight of dry-powder composition.
  • the joint compound compositions according to this disclosure may be formulated as dry-powder compositions or they can be premixed with water as a ready-mixed joint compound. If a powdered joint compound is used, then a user may add water prior to application of the joint compound to a substrate. Water may be added in amounts producing a paste. The amount of water to be used depends on customer preferences. In some embodiments, about 40 cc to about 70cc of water may be added per 100 grams of powdered composition.
  • Preferred joint compound compositions according to this disclosure when mixed with water, include those which have a viscosity in the range from about 150 to about 1,000 Brabender Units (11850-79000 cps) and more preferably from about 300 to about 500 Brabender Units (23700-39500 cps).
  • a Brookfield viscosity is measured at room temperature using a VC-3 Brabender viscometer with a 250 centimeter-gram torsion head operated at a 72-78 r.p.m. spindle speed.
  • the joint compound composition according to this disclosure may comprise dry components and liquid components or they can be formulated with dry components only. If liquid components are to be used in the dry-powder formulations, liquid components may be supplied in a separate container. In ready-mixed formulations, all components, but the set accelerator, may be premixed into a paste.
  • Fig. 2 it reports a comparative analysis for perlite-free, lightweight setting-type joint compounds according to this disclosure in comparison to control EASY SANDTM compound which comprises perlite.
  • the present perlite-free, lightweight setting-type joint compounds are characterized by low shrinkage, improved sandability (easy sanding), and excellent adhesion to paper tape.
  • Formulations referred to in Fig. 2 are listed in Examples 1 and 2.
  • Dry Density for each sample was measured by filling a cylinder of known volume with a sample of known weight and calculating the density by dividing the weight by volume.
  • Density (weight of compound in cup/weight of water in cup)*8.345. Units are in Ibs/gal.
  • Sanding Ease Sandability was measured as follows. Each sample was applied over a 50-mil thickness template and each sample was placed in a stable environmental chamber or room. Once a sample was dried, its weight was measured. Each sample was placed on Gardner Abrasion tester with 150-grit sandpaper for 5 oscillating strokes. Each sample was weighed post sanding and a percentage of removed material was recorded.
  • Tape Bond 75/50 was conducted essentially as described in U.S. Patent 4,657,594, the entire disclosure of which is herein incorporated by reference in its entirety. Briefly, paper tape was embedded in joint compound mixed with water on gypsum wallboard as follows. First, a layer of joint compound was applied to the gypsum wallboard. Then, the paper tape was laid over the joint compound and embedded with a board knife. Then, additional joint compound was applied on top and made smooth.
  • Bond to paper tape was then measured by estimating the amount of delaminated paper left on the joint compound after making a 5 inch “X” cut in sections of bonded tape, and then peeling the tape from the joint compound. Bond values of “0 to 7” were assigned depending on how much delaminated paper tape remained bonded to the joint compound. A 5-inch joint compound section completely covered with delaminated tape was assigned a “7” bond value, and a section showing no paper tape was given a “0” bond rating
  • Bonds labeled 75/50 were dried at 75° F and 50% relative humidity for both one day Cold bonds were dried at 40° F and 80% relative humidity for one day Redried bonds were cold bonds redried in 75/50 conditions for one day.
  • Shrinkage was measured as follows. A sample was applied over a 200-mil thickness template and each sample was placed in a stable environmental chamber or room. Samples were allowed to fully dry over 24-hours. Once a sample was fully set, the thickness of the dried sample was measured.
  • Vicat Set was measured as follows. The setting time of the samples was measured substantially following a modified ASTM C-472 (Standard Test Methods for Physical Testing of Gypsum, Gypsum Plasters and Gypsum Concrete, ASTM International, West Conshohocken, PA). In summary, approximately 300 g of material was weighed into a half-pint container at previously determined use consistency. Upon stiffening, a 300-g Vicat needle was held above the surface and allowed to penetrate freely into the sample. The setting time is defined as the time at which only 50% of the needle penetrates the joint compound surface.
  • the perlite-free, lightweight setting-type joint compounds according to this disclosure meet or even exceed the requirements for sandability, crack-resistance and adhesion to a substrate, while these compounds do not contain perlite, therefore minimizing production of respirable silica particles during manufacturing and while sanding.
  • the joint compound of this disclosure is optimized to have a smooth and creamy texture with balanced body (thixotropy) and slip/flow.
  • the foam structure could alter these properties.
  • surface defects be it either craters, pinholes, cracking, or an overly rough surface arising from surfactant incorporation in the formula would be detrimental.
  • Surface defects could present either immediately after application (cratering, pinholing) or after setting (cratering, pinholing, cracking), and it could be made worse if they could not be remedied by sanding or other post-finishing steps.
  • the joint compounds compositions according to this disclosure produce a smooth surface which is substantially free of surface defects. This result is highly unexpected because foaming agents are known to produce air bubbles and a person of skill would not expect to produce a monolithic surface when using a foaming agent.
  • this disclosure provides methods for making the joint compounds according to this disclosure.
  • the joint compound can be formulated as a dry powder or as a ready-mixed setting-type joint compound premixed with water.
  • Some dry -powder compositions may be formulated with all dry components.
  • a user simply adds water and optionally some additional additives, e.g., one or more set accelerators, just prior to applying the joint compound to a substrate.
  • the dry powder joint compounds according to this disclosure may comprise one or more liquid additives.
  • all dry components may be first mixed into a first mixture.
  • Liquid components may be mixed with some amount of water into a second mixture.
  • the second mixture may be provided in a separate container, and it can be mixed with the first mixture and additional water, if necessary, by a user prior to application to a substrate.
  • the setting-type joint compound according to this disclosure may be formulated as a ready-mixed setting type joint compound.
  • all dry components, except for the set accelerator are mixed into a first mixture and all liquid components except for the set accelerator, and some amounts of water are mixed together into a second mixture.
  • the first mixture is then mixed with the second mixture, producing a ready-mixed setting type joint compound.
  • a set accelerator may be supplied in a separate container. The set accelerator can be added to the ready-mixed setting type joint compound by a user just prior to applying the joint compound to a substrate.
  • this disclosure relates to various methods in building construction and surface repair projects.
  • the perlite-free, lightweight setting-type joint compounds according to this disclosure may be used in various applications, including as an all-purpose joint compound and/or as a finishing compound. Further applications may include various repair projects, including for patching cracks, holes and/or indentations.
  • the present perlite-free, lightweight setting-type joint compounds can be applied over a variety of different substrates, including, but not limited, to wallboard, plaster, cementitious substrate, wood and/or joint tape as may be needed when finishing seams (joints) between two abutting wallboards.
  • the perlite-free, light weight setting-type joint compounds according to this disclosure are particularly suitable for building a wall assembly.
  • wall assemblies include those described in U.S. Patent 9,249,578, the entire disclosure of which is herein incorporated by reference.
  • Embodiments of a wall assembly according to this disclosure may comprise three gypsum panels attached (affixed) to framing members (studs) of the frame with fasteners. Some or all of the framing members may be coated with an adhesive in order to improve attachment of the gypsum panels to the frame.
  • the framing members are wood studs or a metal framing.
  • the adjoining gypsum panels meet with their abutting edges at a seam, which can be referred in this disclosure as a joint.
  • the joint may be filled with the pcrlitc-frcc, lightweight setting type joint compound of this disclosure and preferably, a liquid-permeable paper tape or fiberglass tape is then embedded into the joint compound.
  • a second coating of the joint compound according to this disclosure may be applied over the joint as a top-coat.
  • a third or finish coating of the joint compound may then be applied and allowed to set.
  • the joint compound according to this disclosure can be used as an all-purpose joint compound in each of the three applications: for filling joints, as a top-coat and as a finish-coat.
  • the joint compound according to this disclosure may be used in combination with conventional joint compounds.
  • a conventional joint compound may be used for filling a joint, while the joint compound according to this disclosure may then used as a top-coat and/or as finish-coat.
  • the application methods may further comprise sanding the joint compound after the joint compound set and optionally, applying a primer and/or paint.
  • Various methods can be used for applying the joint compound of this disclosure to the substrate, including with a joint knife and/or by spraying.
  • Various perlite-free, lightweight setting type joint compounds were prepared according to formulations listed below.
  • liquid additives were first mixed together with water in a mixing bowl.
  • the dry powder additives were then added.
  • the ingredients were either mixed by hand in a stainless steel mixing bowl for one minute, or, alternatively, they were mechanically mixed for one minute using a Hamilton Beach® Variable-Speed Hand Mixer in the same stainless steel bowl.
  • compositions listed in Table 1 Perlite-free formulations and composition by dry weight percentage.
  • Surfactants DDB SA
  • cosurfactants CAPB
  • foaming thickeners MHEC and carboxymethyl cellulose
  • xanthan gum were evaluated.
  • Various perlite-free, lightweight setting type joint compounds were prepared according to formulations listed below in laboratory quantities.
  • liquid additives were first mixed together with water in a mixing bowl.
  • the dry powder additives were then added.
  • the ingredients were either mixed by hand in a stainless steel mixing bowl for one minute, or, alternatively, they were mechanically mixed for one minute using a Hamilton Beach® Variable-Speed Hand Mixer in the same stainless steel bowl.
  • compositions were as listed in Table 3 below. Perlite-free formulations and composition by dry weight percentage for the 1714 Series. Surfactants (DDBSA), cosurfactants (CAPB), foaming thickeners (Tylose 60,000 YP4) were evaluated.
  • DBSA Surfactants
  • CAPB cosurfactants
  • foaming thickeners Teylose 60,000 YP4
  • Results from tests in Tables 2 and 4 are also summarized in a matrix of Fig. 2, comparing key performance properties of the perlite-free, lightweight setting-type joint compounds of this disclosure to a control joint compound which comprises perlite.
  • results were divided into the following groups as shown in Table 5.

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Abstract

L'invention concerne des composés pour joints de type à prise rapide, sans perlite, comprenant du sulfate de calcium hémihydraté ayant une densité sèche inférieure à 50 lb/ft3, un agent moussant ayant une balance HLB supérieure ou égale à 10 et comprenant de préférence un acide alkylbenzène sulfonique ayant une chaîne alkyle linéaire contenant entre 8 et 14 atomes de carbone et/ou un sel de celui-ci, et une combinaison de modificateurs de rhéologie. L'invention concerne également des procédés de construction d'ensembles de panneaux muraux et des procédés pour des projets de réparations et de retouches murales qui comprennent l'application des composés pour joints de type à prise rapide sans perlite sur un substrat.
PCT/US2023/078200 2022-11-04 2023-10-30 Compositions de composés pour joints de type à prise rapide sans perlite WO2024097659A2 (fr)

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US18/205,074 US20240150244A1 (en) 2022-11-04 2023-06-02 Perlite-free, lightweight setting-type joint compound compositions
US18/205,074 2023-06-02

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