Joint compounds, activators and methods for setting a joint compound and preventing seed setting

Patent metadata

Field	Value
Publication number	US-2019135697-A1
Application number	US-201816139350-A
Country	US
Kind code	A1
Filing date	Sep 24, 2018
Priority date	Nov 7, 2017
Publication date	May 9, 2019
Grant date	—

Abstract

A ready-mixed setting type joint compound in which formation of gypsum seeds has been inhibited. A method for controlling a setting reaction by mixing a ready-mixed setting type joint compound with one or more metal ion control agents comprising aminopolycarboxylic acid and/or a salt thereof, and further mixing the setting type joint compound with one or more non-calcium phosphate compounds. The method may further comprise mixing the setting type joint compound with a set activator obtained by blending together a first set activator including a cadmium compound, lead compound and/or zinc compound and a second set activator including a ferrous compound, aluminum compound and/or manganese compound.

First claim

What is claimed is:

1 . A method for inhibiting formation of gypsum seeds in a ready-mixed setting type joint compound, the method comprising:
mixing at least calcined gypsum, water, at least one non-calcium phosphate compound and at least one metal ion control agent comprising an aminopolycarboxylic acid and/or a salt thereof, and thereby obtaining a ready-mixed setting joint compound; and thereby inhibiting formation of gypsum seeds in the joint compound.

2 . The method of claim 1 , wherein the method further comprises:
blending together a first set activator comprising a cadmium compound, lead compound and/or zinc compound and a second set activator comprising a ferrous compound, aluminum compound and/or manganese compound, and thereby obtaining a set activator blend; and mixing the set activator blend with the ready-mixed setting type joint compound and thereby controlling the setting reaction of the ready-mixed setting type joint compound.

3 . The method of claim 2 , wherein the first set activator is zinc oxide, zinc hydroxide and/or zinc salt and wherein the second set activator is aluminum oxide, aluminum hydroxide and/or aluminum salt.

4 . The method of claim 2 , wherein the first set activator is zinc sulfate and wherein the second set activator is alum.

5 . The method of claim 2 , wherein the first set activator is zinc sulfate and wherein the second set activator is alum, and wherein the zinc sulfate and alum are used in a ratio in the range from 3:1 to 1:1 by dry weight of zinc sulfate to alum.

6 . The method of claim 2 , wherein the first set activator is zinc sulfate and wherein the second set activator is alum, and wherein the zinc sulfate and alum are used in a ratio in the range from 3:1 to 1:1 by dry weight of zinc sulfate to alum and wherein the set activator blend is mixed with the setting type joint compound in an amount in the range from 0.5% to 5% by weight of dry ingredients in the setting type joint compound.

7 . The method of claim 1 , wherein the setting type joint compound is a ready-mixed setting type joint compound.

8 . The method of claim 1 , wherein the non-calcium phosphate compound comprises zinc hexametaphosphate, potassium tripolyphosphate, tetra sodium pyrophosphate, tetra potassium pyrophosphate, sodium tripolyphosphate, mono-ammonium phosphate, monobasic potassium phosphate, or any combination thereof.

9 . The method of claim 1 , wherein the metal ion control agent comprises diethylenetriamine pentaacetic acid (DTPA), pentasodium diethylenetriamine pentaacetate, calcium trisodium diethylenetriamine pentaacetate, ethylenediamine tetraacetic acid (EDTA), sodium calcium edetate, hydroxy-ethyl-ethylene-diaminetriacetic acid (HEDTA), trisodium N-(hydroxyethyl)-ethylenediaminetriacetate, or any combination thereof.

10 . The method of claim 1 , wherein from about 0.01% to about 10% by weight of the metal ion control agent is used, calculated as a percentage of the weight of dry calcined gypsum.

11 . The method of claim 1 , wherein from about 0.01% to about 10% by weight of the non-calcium phosphate compound is used, calculated as a percentage of the weight of dry calcined gypsum.

12 . The method of claim 1 , wherein the metal ion control agent comprises pentasodium diethylenetriamine pentaacetate in an amount from about 0.01% to about 10% by weight, based on the weight of dry calcined gypsum and wherein the non-calcium phosphate compound comprises tetra-potassium pyrophosphate (TKPP) in an amount from about 0.01% to about 10% by weight and/or tetra-sodium pyrophosphate (TKPP) in an amount from about 0.01% to about 10% by weight, all calculations based on the weight of dry calcined gypsum.

13 . The method of claim 1 , wherein at least one of the following is further mixed with the setting type joint compound: a binder, calcium carbonate, mica, talc, clay, a low molecular weight polymer, or any combination thereof.

14 . The method of claim 2 , wherein the first activator is zinc sulfate and the second activator is alum, the setting type joint compound comprises calcium carbonate and the mixing is performed at a temperature in the range from 40° F. to 75° F.

15 . The method of claim 2 , wherein the first activator is zinc sulfate and the second activator is alum, the ratio of zinc sulfate to alum is from 3:1 to 1:1 by dry weight, the joint compound comprises calcium carbonate and the mixing is performed at a temperature in the range from 40° F. to 65° F., and wherein the set activator blend is added in an amount from 0.5% to 5% by weight to the setting joint compound, excluding water.

16 . A ready-mixed setting type joint compound comprising calcined gypsum, water, at least one retarder of the calcined gypsum setting reaction and between 0.01% to 10% of a metal ion control agent comprising an aminopolycarboxylic acid and/or a salt there of by weight, based on the weight of calcined gypsum and the ready-mixed setting type joint compound further comprising between 0.01% to 10% of non-calcium phosphate compound by weight, based on the weight of calcined gypsum.

17 . The ready-mixed setting type joint compound of claim 16 , wherein the metal ion control agent comprises diethylenetriamine pentaacetic acid (DTPA), pentasodium diethylenetriamine pentaacetate, calcium trisodium diethylenetriamine pentaacetate, ethylenediamine tetraacetic acid (EDTA), sodium calcium edetate, hydroxy-ethyl-ethylene-diaminetriacetic acid (HEDTA), trisodium N-(hydroxyethyl)-ethylenediaminetriacetate, or any combination thereof.

18 . The ready-mixed setting type joint compound of claim 16 , wherein the non-calcium phosphate compound comprises zinc hexametaphosphate, potassium tripolyphosphate, tetra sodium pyrophosphate, tetra potassium pyrophosphate, sodium tripolyphosphate, mono-ammonium phosphate, monobasic potassium phosphate, or any combination thereof.

19 . The ready-mixed setting type joint compound of claim 16 , wherein the metal ion control agent comprises pentasodium diethylenetriamine pentaacetate, and wherein the non-calcium phosphate compound comprises tetra potassium pyrophosphate, tetra sodium pyrophosphate or any combination thereof.

Assignees

• United States Gypsum Co

Inventors

• Rosenthal Guy L
• Miller Charles J
• Kincaid Tyler
• Schlude Joseph

Classifications

• C04B22/10

  containing carbon in the anion, e.g. carbonates · CPC title

• C04B22/142

  Sulfates · CPC title

• C04B22/16

  containing phosphorus in the anion, e.g. phosphates · CPC title

• C04B24/123

  Amino-carboxylic acids · CPC title

• C04B28/14 Primary

  containing calcium sulfate cements {(gypsum-paper plates E04C)} · CPC title