Spray-applied joint compound, wall assembly, and methods and products related thereto

Patent metadata

Field	Value
Publication number	US-9365455-B2
Application number	US-201514736861-A
Country	US
Kind code	B2
Filing date	Jun 11, 2015
Priority date	Sep 25, 2012
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

Provided are compositions and methods for expeditious wall installation by spray-applying a joint compound comprising a polymeric binder and hollow spheres.

First claim

What is claimed is:

1. A drying-type joint compound with a shrinkage of less than 15% by volume as measured according to ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof;
wherein the hollow spheres are composed of self-contained air bound by a solid barrier and wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and
where the density of the spheres are from about 0.0015 lb/in 3 (about 0.04 g/cm 3 ) to about 0.04 lb/in 3 (about 1.1 g/cm 3 ); and
wherein the drying-type joint compound has the viscosity in the range from about 15,600 cP to about 23,000 cP as measured according to ASTM C474-05.

2. The joint compound of claim 1 , wherein the binder in the joint compound is an acrylic acid polymer or acrylic acid copolymer.

3. The joint compound of claim 1 , wherein the binder in the joint compound is in the form of an aqueous emulsion.

4. The joint compound of claim 1 , wherein the joint compound exhibits a shrinkage of about 2% or less, as measured by ASTM C474-05.

5. The joint compound of claim 1 , wherein the joint compound is substantially free of at least one of the following: setting minerals, bulk filler, clays, starch, mica, calcium carbonate, expanded perlite, calcium magnesium carbonate, limestone, calcium sulfate dihydrate, attapulgite clay, kaolin clay, talcs, diatomaceous earth, or a combination thereof.

6. The joint compound of claim 1 , wherein the hollow spheres are selected from the group consisting of lime boro-silicate, polystyrene, ceramic, recycled-glass, expanded glass, and lightweight polyolefin beads, thermoplastic, thermoset, and any combination thereof.

7. The joint compound of claim 1 , wherein the joint compound comprises:
(a) a latex emulsion binder in the amount from about 3% to about 90% by weight of the wet composition;
(b) the hollow spheres are present in the amount from about 5% to about 25% by weight of the wet composition;
(c) a nonionic surfactant in the amount from about 0.001% to about 5% by weight of the wet composition; and
(d) a humectant in the amount from about 0.001% to about 3% by weight of the wet composition.

8. The joint compound of claim 7 , wherein the joint compound further comprises at least one of the following:
(a) a defoamer in the amount from about 0.05% to about 5% by weight of the wet composition;
(b) a rheological modifier in the amount from about 0.1% to about 5% by weight of the wet composition;
(c) a biocide, in the amount from about 0.1% to about 1.5% by weight of the wet composition;
(d) at least one of calcium carbonate and limestone in the amount from about 1% to about 40% by weight of the wet composition; and
(e) delaminated clay in the amount from about 0.1% to about 5% by weight of the wet composition.

9. The joint compound of claim 1 , wherein the joint compound consists essentially of:
(a) a latex emulsion binder in the amount from about 3% to about 90% by weight of the wet composition;
(b) the hollow spheres are present in the amount from about 5% to about 25% by weight of the wet composition;
(c) a nonionic surfactant in the amount from about 0.001% to about 5% by weight of the wet composition;
(d) a humectant in the amount from about 0.001% to about 3% by weight of the wet composition; and
(e) water.

10. A wall installation method, the method comprising:
(a) obtaining a first gypsum board and a second gypsum board;
(b) obtaining a drying-type joint compound with the viscosity from about 15,600 cP to about 23,000 cP as measured by ASTM C474-05, and a shrinkage of less than 15% by volume as measured by ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof; wherein the hollow spheres are composed of self-contained air bound by a solid barrier and wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and where the density of the spheres are from about 0.0015 lb/in 3 (about 0.04 g/cm 3 ) to about 0.04 lb/in 3 (about 1.1 g/cm 3 );
(c) joining the two boards together such that the edges of the two boards create a seam; and
(d) spraying the seam with the drying type joint compound, until the seam is filled with the joint compound.

11. The method of claim 10 , wherein each of the boards is having at least one tapered edge with a recess depth at the deepest point from about 0.005 inch to about 0.05 inch.

12. The method of claim 11 , wherein the installation is completed in less than 24 hours.

13. The method of claim 10 , wherein the joint compound is applied in one coat only.

14. The method of claim 10 , wherein the seam between the first board and second board is further reinforced with a joint tape.

15. The method of claim 10 , wherein the first board and the second board comprise of a gypsum core sandwiched between two sheets of paper.

16. The method of claim 10 , wherein the seam is sanded after it is filled with the joint compound and the joint compound is dried.

17. The method of claim 10 , wherein the installation is completed in less than 48 hours.

18. The method of claim 10 , wherein the step of obtaining the drying-type joint compound is performed by formulating the joint compound consisting essentially of:
(a) a latex emulsion binder in the amount from about 3% to about 90% by weight of the wet composition;
(b) wherein the hollow spheres are present in the amount from about 5% to about 25% by weight of the wet composition;
(c) a nonionic surfactant in the amount from about 0.001% to about 5% by weight of the wet composition;
(d) a humectant in the amount from about 0.001% to about 3% by weight of the wet composition;
(e) a defoamer in the amount from about 0.05% to about 5% by weight of the wet composition;
(f) a rheological modifier in the amount from about 0.1% to about 5% by weight of the wet composition;
(g) a biocide, in the amount from about 0.1% to about 1.5% by weight of the wet composition;
(h) at least one of calcium carbonate and limestone in the amount from about 1% to about 40% by weight of the wet composition;
(i) delaminated clay in the amount from about 0.1% to about 5% by weight of the wet composition; and
(j) water.

19. The method of claim 10 , wherein the viscosity of the joint compound is measured prior to the joint compound is spray-applied to the seam.

20. A method preparing a joint compound for spray application, the method comprising:
(a) preparing a composition comprising a latex emulsion binder in the amount from about 3% to about 90% by weight of the wet composition; a plurality of hollow spheres having an average isostatic crush strength of at least about 250 psi, as measured according to ASTM D3102-78, wherein the spheres are present in the amount from about 5% to about 25% by weight of the wet composition; a nonionic surfactant in the amount from about 0.001% to about 5% by weight of the wet composition; and a humectant in the amount from about 0.001% to about 3% by weight of the wet composition;
(b) measuring the viscosity of the composition according to ASTM C474-05; and
(c) adjusting the viscosity of the compos

Assignees

• United States Gypsum Co

Inventors

• Hargrove Pamela L
• Moyer Jr Kevin W
• Bury Rafael
• Negri Robert

Classifications

• C04B14/301

  porous or hollow · CPC title

• C04B26/00 Primary

  Compositions of mortars, concrete or artificial stone, containing only organic binders {, e.g. polymer or resin concrete (mechanical aspects of moulding polymer or resin concrete B29C67/242)} · CPC title

• C04B2103/67

  Biocides · CPC title

• C04B14/24

  porous, e.g. foamed glass · CPC title

• C08K7/16

  Solid spheres · CPC title