joint compound, wall mount and related method

专利摘要:
JOINT COMPOUND, WALL MOUNT AND METHODS AND PRODUCTS RELATED TO THEM. Aspects of plate finishing systems are disclosed. For example, in several respects, joint compound compositions, wall mounts, methods for treating walls, and products related to any of the above are disclosed, including reinforcement trim, for example, to protect the corners where the boards meet, fasteners and tape. The joint compound is preferably a drying-type composition with reduced shrinkage properties, and includes binder and hollow spheres, resulting in an ultralight formulation in some embodiments. The joint compound composition can be applied in a one-layer treatment in preferred embodiments. Other aspects of the plate finishing system accommodate such a one-layer treatment to thereby allow a user to manipulate the compound closer to the plate plane compared to conventional formulations. Gasket tape and reinforcement trim may include non-expandable synthetic paper liner material in some embodiments.
公开号:BR112015005932B1
申请号:R112015005932-5
申请日:2013-09-25
公开日:2021-01-19
发明作者:Rafael Bury；Robert H. Negri；Mark Miklosz；Pamela Hargrove
申请人:United States Gypsum Company；
IPC主号:

专利说明:

BACKGROUND OF THE INVENTION
[0001] In civil construction, different types of roofs are used as panels to form ceiling and internal and external wall surfaces. For the sake of simplicity, as used in this document, it will be understood that the term "wall" also encompasses ceilings. Typically, the covers are in the form of plates (also referred to as panels) molding members such as in balloon framing arrangements known in the art. Examples of coverings include plasterboard coated with paper, fibrous sheets (for example, fiberglass) and the like. These and other types of plates are usually cut to appropriate dimensions and then attached to the molding members, for example, with screws, nails, or the like to form wall sections formed from multiple plates.
[0002] Such wall sections are usually finished to provide aesthetically pleasing, uniform and protected surfaces. For example, two tiles side by side arranged in the same plane will form a joint seam between them in the vertical walls and horizontal ceilings. To finalize the splice, joint reinforcement tape is incorporated into the splice, together with a layer of joint compound under the tape and multiple layers of joint compound applied over the tape. Some plates meet at an angle such as when forming a corner. Reinforcement bead can be attached directly to the board using fasteners, or a layer of joint compound is applied under the chip to adhere the reinforcement bead to the board. The installed reinforcement is then hidden with multiple layers of joint compound applied to the chip. Fasteners used to affix the plate to the framing members must also be concealed with multiple layers of joint compound applied over them. After the various applications of joint compound are dried, the resulting wall surfaces can be sanded and painted to form the desired uniform and aesthetically pleasing appearance.
[4] The level of finish as described above may vary. For example, in relation to plasterboard drywall, six (6) levels of finishing of the plasterboard are comprised in the technique, ranging from zero (without treatment) to level five (the highest level of finish), as defined in the document association of the Gypsum Association GA-214 and the American Society for Testing and Materials ("ASTM") C840. The level of finish generally corresponds to the number of joint compound applications for seams, shavings and fasteners. Levels three, four and five are normally used for occupied spaces within buildings. For single-family homes, level 4 is the most common that is implemented. Level five is less frequently used and generally requires the application of a plaster layer of joint compound over the entire surface of the wall.
[5] Conventional approaches to finishing wall mounts as described above were not fully satisfactory. The materials conventionally used to finish the wall mounts create significant inefficiencies in the process and also require an advanced level of skill to use effectively. For example, existing joint compounds require three separate layers to be applied to fasteners, as well as multiple layers applied to flat seams between plates in the same plane and corner seams. Each layer must dry separately, which introduces significant downtime in the construction process, particularly since other construction businesses cannot normally work inside the building, while the wall finish occurs. Each layer of joint compound may require about a day to dry, and it usually takes about a week to install the plasterboard and finish the flat joints, fasteners and corner shavings for a typical new construction for a 2,400-foot house square meters (222.97 square meters) of living space (corresponding to about 10,000 square feet - 929 square meters - of slab).
[6] In addition, the need to apply multiple layers of joint compound requires the user to manipulate the joint compound significantly above the plane of the plate. To allow the board to appear smooth to the naked eye (even if it is not), significant skill and labor is required to achieve the proper visual appearance when the user is working above the plane of the board. The additional layers of joint compound must be spread rapidly over the seam more and more gradually in order to make the seam appear aesthetically smooth. If the user is not significantly qualified, the visual appearance will not be satisfactory.
[7] It will be appreciated that this description of fundamentals was created by the inventors to assist the reader, and should not be taken as a reference to the state of the art or as an indication that any of the problems themselves indicated have been appreciated in the art. While the principles described can, in some respects and modalities, alleviate the problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the appended claims and not by the capacity of the claimed invention to solve any specific problem noted in this document. BRIEF SUMMARY OF THE INVENTION
[8] In one aspect, the invention provides a drying type gasket compound composition. The joint composition comprises, consists of or consists essentially of a binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof. The composition also comprises a plurality of hollow spheres. The balls desirably have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78.
[9] In another aspect, the invention provides a joint compound composition consisting essentially of (a) latex emulsion binder in an amount of about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow spheres having an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78, wherein the spheres are present in an amount of about 5% to about 25% by weight of the wet composition; (c) nonionic surfactant in an amount of about 0.001% to about 5% by weight of the wet composition; and humectant (d) in an amount of about 0.001% to about 3% by weight of the wet composition; and, optionally, defoamer (e) in an amount of about 0.05% to about 5% by weight of the wet composition; (f) rheological modifier in an amount of about 0.1% to about 5% by weight of the wet composition; (g) biocide, in an amount of about 0.1% to about 1.5% by weight of the wet composition; (h) bulk filler, such as calcium carbonate or limestone, in an amount of about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of about 0.1% to about 5% by weight of the wet composition.
[10] In another aspect, the invention provides a wall mount comprising, consisting of or consisting essentially of two adjacent plates, joined by a splice. Only one layer of the joint compound is applied over the splice to provide a uniform aesthetic appearance. The joint compound composition comprises binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof. The composition also comprises a plurality of hollow spheres. The balls desirably have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78. The wall mount additionally comprises a flat, non-expandable, dimensionally stable joint tape incorporated into the seam.
[11] In another aspect, the invention provides a method of treating a drywall assembly of two adjacent boards joined by a splice. The method comprises, consists of or consists essentially of applying joint tape and a layer of the joint compound composition to the splice. The joint compound composition comprises binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof. The composition also comprises a plurality of hollow spheres. The balls desirably have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78. The method further comprises drying the composition.
[12] In another aspect, the invention provides a reinforcement chip to protect a splice of two adjacent plates with opposite front and rear surfaces, the faces being arranged with respect to each other at an angle between the faces of the plate. The chip comprises, consists of or consists essentially of a paper face comprising non-expandable synthetic paper covering material and a liner. For example, the coating material can be laminated with a firm, rust-resistant material designed to provide superior long-term corner angle joint reinforcement that exceeds the minimum performance requirements set out in ASTM C1047-10a (Standard Specification for Plaster Drywall Accessories and Plaster Varnish Base) for resistance to cracking and splintering, resulting in the corner vertex that remains in a straight line during the normal movement and / or displacement of the building and daily wear and tear. In some embodiments, the liner comprises metals such as galvanized steel and / or other liner material having the desired properties mentioned above, including, for example, composite laminate structure, layered paper, thermoplastics, thermosets, carbon fiber, polyester , polycarbonate, twisted polyolefin, natural or synthetic fiber, woven material and the like. BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE FIGURES
[13] FIG. 1 is a perspective view of a wall mount.
[14] FIGS. 2A-2B are alternative section views taken substantially from line 2-2 of FIG. 1, wherein FIG. 2A illustrates a conventional taper for comparison purposes, while FIG. 2B illustrates a shallower taper in accordance with the modalities of the invention.
[15] FIGS. 3A-3B are alternative section views of a finished joint of two drywalls with contiguous tapered edges, in which FIG. 3A illustrates a joint with the conventional wide dispersion of joint compound for comparison purposes, while FIG. 3B illustrates the narrower dispersion of the joint compound, closer to the plane of the plate, in accordance with the modalities of the invention.
[16] FIGS. 3C-3D are alternative section views of a finished joint of two drywalls with square (ie, not tapered) contiguous edges, in which FIG. 3C illustrates a conventional joint with the extensive dispersion of joint compound for comparison purposes, while FIG. 3D illustrates the narrower dispersion of the joint compound, closer to the plane of the plate, in accordance with the modalities of the invention.
[17] FIGS. 4A and 4B are exploded perspective views depicting the reinforcement chip to be applied to a corner formed from two drywalls, in which FIG. 4A shows an outer corner with an angle (x), while FIG. 4B shows an inner corner with an angle (y).
[18] FIG. 5 illustrates two adjunct plates affixed to a molding skeleton, in which the V-shaped cut shows the presence of adhesive on the molding members in accordance with the modalities of the invention.
[19] FIGS. 6-7 illustrate the wall mount installations, where FIG. 7 illustrates a finished room installation after painting and FIG. 8 illustrates tapered joints before depositing the joint compound.
[20] FIG. 8 depicts the trim of corner reinforcements in accordance with the modalities of the invention.
[21] FIG. 9 depicts the corner reinforcement chip being affixed to a corner inside with a pressure adhesive in accordance with the modalities of the invention.
[22] FIGS. 10-11 depict a reinforcement path at rest in the corners with a roller device in accordance with the modalities of the invention.
[23] FIG. 12 depicts the trim of corner reinforcements in accordance with the modalities of the invention.
[24] FIG. 13 depicts wall mounts showing corner reinforcement shavings installed in the inner and outer corners in accordance with the modalities of the invention.
[25] FIG. 14 depicts a reinforcement chip for an interior corner with a layer of joint compound in accordance with the modalities of the invention.
[26] FIG. 15 depicts a finish of a sanded layer both for a joint in the machine direction (horizontal, as shown) and for a rear joint (vertical, as shown) in accordance with the modalities of the invention.
[27] FIG. 16 depicts installation of wall mounting with joint treatment applied.
[28] FIG. 17 depicts a wall mount treated with a V-cut to show the adhesive molding member and a layer of joint compound illustrating narrow dispersion in accordance with the modalities of the invention.
[29] FIG. 18 depicts a conventional joint treatment system with joint tape incorporated into joint compound with two additional joint compound applications on the tape that require extensive dispersion of the joint compound for comparison purposes.
[30] FIGS. 19-21 illustrate the progression of a flexural strength test for sample 2A of Example 2 for comparison purposes.
[31] FIGS. 22-24 illustrate the progression of a flexural strength test for sample 2B of Example 2 for comparison purposes.
[32] FIGS. 25-27 illustrate the progression of a flexural strength test for sample 2C of Example 2, in accordance with the modalities of the invention.
[33] FIGS. 28-29 depict the flexural strength for sample 2C of Example 2, in accordance with the modalities of the invention.
[34] FIG. 30 is a box diagram showing the displacement of stress when the first crack was observed and measured in inches (y-axis), and various joint compounds in accordance with the modalities of the invention, and comparative examples (x-axis).
[35] FIG. 31 is a box diagram showing the load (lbs) when the first crack was observed and measured in pounds (lbs), and various joint compounds in accordance with the modalities of the invention, and comparative examples (x-axis).
[36] FIG. 32 is a box diagram showing the shear displacement when the first crack was observed and measured in inches (y-axis), and several joint compounds in accordance with embodiments of the invention, and comparative examples (x-axis).
[37] FIG. 33 is a box diagram showing the peak shear displacement when the first crack was observed and measured in inches (y-axis), and various joint compounds in accordance with embodiments of the invention, and comparative examples (x-axis).
[38] FIG. 34 is a box diagram showing the shear displacement ratio (ie, a peak displacement ratio in the failure of the joint system for displacement in the first crack) (y-axis) and various joint compounds in accordance with the modalities of the invention and comparative examples (x-axis).
[39] FIG. 35A illustrates a structure mounting system by ASTM E72 modified with an assembly of 8 'x 8' (about 2.4 mx about 2.4 m), prepared from 2 "x 4" wooden struts ( about 5 cm x about 10 cm). Wooden struts are not shown.
[40] FIG. 35B illustrates the modified ASTM E72 frame assembly system of FIG. 35A configured with 2 "x 4" wooden struts placed 16 inches (about 0.4 m) apart.
[41] FIG. 35C illustrates the modified ASTM E72 frame assembly system of FIG. 35B, where the lower part was rigidly fixed to the structure, and a force was applied in the upper left corner by a hydraulic ram programmed to execute a sinusoidal waveform with varying amplitudes.
[42] FIGS. 36A to 36C show the drying profile of the joint compounds of the present invention compared to conventional joint compounds for a thick layer, i.e., about 3/16 inch (about 0.5 cm), in which the percentage of evaporated water (y-axis) was plotted against the increasing drying times represented along (x-axis). FIG. 36A shows the drying profiles in a moderate environment, for example, 75 ° F and 50% relative humidity. FIG. 36B shows the drying profiles in a hot and dry environment, for example, 95 ° F and 10% relative humidity. FIG. 36C shows the drying profiles in a cold and humid environment, for example, 40 ° F and 80% relative humidity.
[43] FIGS. 37A to 37C show the drying profiles of the joint compounds of the present invention compared to conventional joint compounds for a thin layer, i.e., about 1/16 inch (about 0.2 cm), in which the percentage of evaporated water (y-axis) was plotted against the increasing drying times represented along (x-axis). FIG. 37A shows the drying profiles in a moderate environment, for example, 75 ° F and 50% relative humidity. FIG. 37B shows the drying profiles in a hot and dry environment, for example, 95 ° F and 10% relative humidity. FIG. 37C shows the drying profiles in a cold and humid environment, for example, 40 ° F and 80% relative humidity. DETAILED DESCRIPTION OF THE INVENTION
[44] In several embodiments, the present invention relates to joint compound compositions, plate finishing systems, wall mounts, wall treatment methods, and products related to any of the foregoing, including reinforcement trim, for example, to protect the corners where the plates meet, fastener and tape. Several aspects of the invention advantageously provide considerable efficiency in the finishing of wall assemblies comprising coatings, such as plaster walls, sheet-coated board (for example, having fiberglass coating) and the like. For example, the present invention allows wall finishing to take place with significantly fewer steps required for any given desired finish level, for example, a level 4 finish in accordance with the Gypsum Association document GA- 214 and / or ASTM C840 ("level 4"). As a result, wall finishing can occur more quickly with less downtime. In addition, wall finishing in accordance with aspects of the invention requires less skill by users when installing the flooring.
[45] One aspect of the invention is based, at least in part, on the interesting discovery of joint composition of joint compound that has low contraction index. As a result, the joint compound can advantageously be applied in fewer layers than conventional joint compounds. In some embodiments, only one layer of joint compound is used on fasteners, joint tape or reinforcement trim. However, if desired, more than one layer (for example, two or three layers) can be applied depending on the desired finish level. For example, conventional systems suffer from significant contraction, such as, for example, exceeding 15%, for example, about 18% or greater. Modalities of the invention provide considerably less contraction. Joint compound modalities also exhibit desirable flexibility properties and can be readily sanded and, desirably, not cracked.
[46] Because the joint compound composition can be applied in fewer layers, advantageously, a user can manipulate the joint compound closer to the plane of the plate. Conventionally, in multilayer systems (eg 3 layers or more), the user must widely disperse the joint compound over a wide radius from the splice to provide a visual illusion of a smooth surface. Significant skill is required for the user to achieve such an appearance, when the thickness of joint compound rises significantly above the plate plane and plate splices. When using a one-layer joint compound in accordance with the modalities of the invention, a user will not need to disperse the joint compound as widely, and less skill is required to achieve a smooth visual appearance. In some embodiments, the plate is specially designed to have a smaller taper than the conventional plate or no taper (ie, square edge) at the longitudinal edges as described in this document.
[47] In other respects, the invention provides for a special non-swellable material that can be used in joint tape as well as for a face layer in the reinforcement chip composite used to hide and protect the corners of the wall where two plates meet they meet at an angle (for example, an "inner" or "outer" corner, as understood in the art). The chip may also include a liner (for example, comprising metal or other material) to provide rigidity and support.
[48] Adhesive can be used in several aspects of the invention. In some embodiments, the adhesive is an aqueous quick-drying adhesive such as an aqueous wall covering adhesive (for example, such as those marketed by Roman Adhesives), an aqueous bonding agent (for example, such as those marketed by United States Gypsum Company) or an aqueous latex emulsion glue (for example, such as those marketed by OSI). For example, such an adhesive can be applied to the molding members to minimize the number of fasteners used to hang the plate. Adhesive can also be used to facilitate the application of the joint tape and reinforcement trim in accordance with embodiments of the invention.
[49] A fastener, in accordance with the modalities of the invention, can be used to accommodate a single layer of joint compound. For example, the fastener may include a concave head design to create a wavy effect, although other fasteners are possible, including staples or other plaster screws. One or more of these various aspects can be combined in a board finishing system in accordance with the modalities of the invention.
[50] Reference is now made to the figures to depict advantageous illustrative modalities of the invention. FIG. 1 depicts a wall mount 100 comprising three plates 110, 112 and 114, which are affixed to the molding members 116 by means of fasteners 118. Any suitable coating can be used as the plate. For example, the plasterboard typically comprises a core comprising a crystalline plaster interlocking matrix with desired additives such as polyphosphate, starch, dispersant, accelerator, retarder, etc., between two cover sheets in a sandwiched structure. The core may optionally comprise a plaster layer arranged on a core surface facing one or both cover sheets. The invention is not limited with respect to the techniques for making the coating, and the plate can be made in any suitable manner as known in the art.
[51] Molding members 116 are desirably provided with adhesive 120 to promote adhesion to plates 110, 112 and 114 and to allow the use of fewer fasteners 118 than those used in conventional systems. Since fasteners need to be covered with joint compound, reducing the number of fasteners is therefore advantageous in terms of efficiency, ease and quality of installation.
[52] Plate edges are generally identified as being longitudinal or transverse based on how the plate is made on the manufacturing line. Edges along the longitudinal are usually the longest edges and are usually packaged with cover sheet (for example, made of paper) during the manufacture of the slab on which a cementitious slurry is deposited on a moving cover sheet (for example , on a mat) to initially form a long, continuous ribbon of precursor to the plate, which eventually is cut transversely to desired dimensions as known in the art (for example, 4 'X 8'; 4 'X 10'; 4 'X 12'; etc., although different lengths and widths are possible, including the 36 inch wide plate or the 54 inch wide plate). For example, plate 110 has longitudinal edges 122 and 124 and crossing edges of machine 126 and 128. Similarly, plate 112 has longitudinal edges 130 and 132 and transverse machine edges 134 and 136, while plate 114 has edges longitudinal lines 138 and 140 and transverse machine edges 142 and 144. As discussed in FIGS. 2A and 2B below, the edges of the machine are usually tapered. The transverse cutting machine edges are usually not tapered.
[53] Two plates can meet in different configurations to form a splice, often referred to as a joint. Since machine edges are tapered while cross machine joints are not tapered, the nature of the joints will vary depending on which edges of the plates meet. When a longitudinal edge of one plate meets a longitudinal plate of another plate, a longitudinal joint is formed where two tapers meet to form a recess. When a transverse edge of one plate meets a transverse edge of another plate, a back joint, without tapering, is formed. As can be seen in FIG. 1, plates 110 and 112 come together to form a longitudinal joint 146 and plates 112 and 114 come together to form a rear joint 148.
[54] To illustrate the tapered edges on the longitudinal plate, reference is made to FIGS. 2A and 2B, which are sectional views, illustrating alternating depths of tapering from plate 110. A plate core 210 has an upper surface 212 and a lower surface 214. Typically, an upper cover sheet facing the upper surface 212 it wraps around the edge of the machine 124 and finds a bottom paper that faces the bottom surface 214. It will be understood that the sandwiched structure of plate 110 with core 210 between two cover sheets is normally formed upside down such that the surface upper 212 is at the bottom. If desired, during manufacture, the plate can be inverted before entering a greenhouse to dry up excess water. Core 210 may optionally comprise plaster layers as known in the art, for example, on the top surface 212 and / or the bottom surface 214.
[55] FIG. 2A shows a conventional taper 216 with a significant depth (D) to thereby define a recess 218. Since the conventional joint compound is susceptible to significant contraction, the depth (D) is large to accommodate the receipt of large amounts of joint compound in recess 218 for incorporating joint tape to compensate for shrinkage after drying. The funnel with a substantial depth (D) is additionally designed to assist the user by reducing the height above the plate plane in which additional layers of joint compound are handled in conventional systems. For example, conventional bottlenecks can set a recess depth of about 0.08 inches at the deepest point. Even with such a conventional depth (D) on the taper, the user must still undesirably manipulate the joint compound considerably high above the plane of the plate.
[56] FIG. 2B illustrates an alternating taper in accordance with the modalities of the invention. A plate core 220 has an upper surface 222 and a lower surface 224. Typically, an upper cover sheet facing the upper surface 222 wraps around the edge of the machine 124 and finds a lower paper that faces the lower surface 224. The core 220 can optionally comprise plaster layers as known in the art, for example, on the top surface 222 and / or bottom surface 224. During manufacture, the plate can be initially formed upside down and inverted as desired as described above.
[57] As seen in FIG. 2B, the taper 226 has a depth (D) that is considerably less than the conventional, as indicated in FIG. 2A. Such a taper 226 defines a recess 228, which is smaller than conventional and is particularly useful with low contraction joint compound in accordance with the modalities of the invention. In some embodiments, no taper is provided even in the longitudinal such that the plate has a square edge (ie, D = zero). Thus, since no taper is possible in several embodiments, taper 226 can define a recess depth at the deepest point from about 0 inches to about 0.05 inches, for example, from about 0 inches to about 0.04 inches, 0 inches to about 0.03 inches, 0 inches to about 0.02 inches, 0 inches to about 0.015 inches, 0.005 inches to about 0.05 inches, 0.005 inches to about 0, 04 inches, 0.005 inches to about 0.03 inches, 0.005 inches to about 0.02 inches, 0.005 inches to about 0.015 inches, 0.01 inches to about 0.05 inches, 0.01 inches to about 0.04 inches, 0.01 inches to about 0.03 inches, 0.01 inches to about 0.02 inches, etc.
[58] FIGS. 3A-3D are sectional views, illustrating different arrangements for the level 4 finish of a joint between the two drywalls. Particularly, FIGS. 3A and 3B illustrate a joint between two tapered plates (for example, adjunct plates along the longitudinal) where FIG. 3A illustrates a conventional system with multiple layers of joint compound for comparative purposes and FIG. 3B illustrates a layer of joint compound in accordance with the modalities of the invention. FIGS. 3C and 3D illustrate a joint where two square edges meet without tapering (for example, at a rear joint or longitudinal joint without tapering). In this regard, FIG. 3C illustrates a conventional multilayer system for comparative purposes, while FIG. 3D illustrates application of a joint compound layer in accordance with the modalities of the invention. While plate cores are shown, it will be understood that cover sheets can be applied as described above.
[59] In FIG. 3A, a plate assembly 300 comprises a first plate 302 having a core 304 and a tapered edge 306. A second plate 308 comprises a core 310 and tapered edge 312. Tapered edges 306 and 312 meet to form a tapered joint 314. Tape 316 is applied over joint 314. Conventional systems require a layer of joint compound 318 to incorporate tape 316 over joint 314. Conventional delivery tools can be used to dispense tape 316 and joint compound layer 318 together. After allowing the joint compound layer 318 to dry, a second layer of joint compound 320 is applied over the tape 316. Then, after the second layer 320 has dried, a third layer of joint compound 322 is applied over the second layer 320. The three layers of joint compound 318, 320 and 322 are required in conventional systems to compensate for the significant contraction resulting from conventional joint compound chemistry.
[60] FIG. 3B depicts a layer system in accordance with illustrative embodiments of the invention. A plate assembly 324 comprises a first plate 326 having a core 328 and a tapered edge 330. A second plate 332 comprises a core 334 and tapered edge 336. It will be understood that the tapered edges 330 and 336, may both have a lower slope than that the conventional tapered edges 306 and 312 depicted in FIG. 3A and as described with reference to FIG. 2B above. Tapered edges 306 and 312 meet to form a tapered joint 338. Tape 340 can be applied over joint 338 by means of adhesive 342. Adhesive 342 can be in any suitable arrangement in relation to tape 340, but in some embodiments the adhesive it is on a lower surface of the tape 340 and, optionally, it is protected by adhesive coating. The adhesive can be any suitable adhesive, for example, applied by pressure (such as by hand, knife, roller or other device). Unlike the conventional arrangement illustrated in FIG. 3A, only one layer of joint compound 344 is required, as shown in FIG. 3B.
[61] FIGS. 3C-3D illustrate alternative modalities for a square sharp joint (ie, without tapering) as it can be used in a square sharp rear joint or longitudinal joint. In FIG. 3C, a plate assembly 346 comprises a first plate 348 having a core 350 and a straight edge 352. A second plate 354 comprises a core 356 and straight edge 358. Straight edges 352 and 358 meet to form a sharp square joint 360. Tape 362 is applied over joint 360. Conventional systems require a layer of joint compound 364 to incorporate tape 362 over joint 360. As noted above, conventional delivery tools can be used to distribute tape 362 and the compound layer of joint 364 joints. After allowing the joint compound layer 364 to dry, a second layer of joint compound 366 is applied over the tape 362. Then, after the second layer 366 has dried, a third layer of joint compound 368 is applied over the second layer. 366. The three layers of joint compound 318, 320 and 322 compensate for the significant contraction in conventional joint compounds.
[62] FIG. 3D depicts a one-layer system for square joints in accordance with illustrative embodiments of the invention. A plate assembly 370 comprises a first plate 372 having a core 374 and a straight edge 376. A second plate 378 comprises a core 380 and straight edge 382. Straight edges 376 and 382 meet to form a sharp square joint 384. Tape 386 can be applied over joint 384 by means of adhesive 388. Adhesive 388 can be in any suitable arrangement in relation to tape 386, but in some embodiments the adhesive is on a lower surface of tape 386 and, optionally, is protected by coating adhesive. The adhesive can be any suitable adhesive, for example, applied by pressure. Unlike the conventional arrangement illustrated in FIG. 3C, only one layer of joint compound 390 is required, as shown in FIG. 3D.
[63] Conventional systems, as shown in FIGS. 3A and 3C, require the three layers of joint compound (318, 320 and 322) and (364, 366 and 368) which results in the user having to manipulate the joint compound significantly above the plane (P) of the plate at a height (H) as shown. The height (H) is even more extreme in sharp square shapes (as is typical in relation to rear joints), as shown in FIG. 3C, insofar as there is no taper below the plane (P) of the plate to receive any compound. For example, the height (H) of conventional systems can be at least about 0.1 inches, for example, at least about 0.125 inches or greater. The user must have significant ability to manipulate the compound to appear smooth to the naked eye when operating so high above the plane of the plate. Usually, the joint compound is progressively dispersed further and further away from the joint compound 314 or 360, respectively. Because of the significant height (H), the dispersion is at a substantial width (W), as shown to give the visual appearance of a smooth covered joint. For example, the width (W) of conventional embodiments as shown in FIGS. 3A and 3C can be at least about 30 inches, for example, about 36 inches or more in conventional systems.
[64] The inventive modalities illustrated in FIGS. 3B and 3D advantageously result in less height (H) and width (W) to deposit and disperse the joint compound compared to (H) and (W) for the corresponding conventional arrangements set forth in FIGS. 3A and 3C, respectively. This is because the user is not required to function as high above the plane (P) of the plate and thus does not need to disperse the compound layer 344 and 390, respectively, as wide as in the conventional systems of FIGS. 3A and 3C. For example, the height (H) in some inventive embodiments may be less than 0.1 inches and, preferably, the height (H) is less than 0.7 inches, such as about 0.0625 inches or less or about 0.05 inches or less (e.g. 0.02 inches to about 0.1 inches, 0.02 inches to about 0.07 inches, 0.02 inches to about 0.0625 inches, about 0, 02 inches to about 0.05 inches, about 0.05 inches to about 0.1 inches, about 0.05 inches to about 0.07 inches, about 0.05 inches to about 0.0625 inches, etc.). Similarly, the width (W) of modalities of FIGS. 3B and 3D for dispersion of joint compound 344 and 390, respectively, can be considerably smaller than the width (W) of the corresponding conventional systems (for example, as shown in FIGS. 3A and 3C). For example, the smallest width (W) of advantageous embodiments of the invention can be about 20 inches or smaller, such as about 18 inches or smaller, 15 inches or smaller, 12 inches or smaller (e.g., about 5 inches to about 20 inches, about 5 inches to about 15 inches, about 5 inches to about 12 inches, about 5 inches to about 10 inches, etc.).
[65] FIGS. 4A and 4B depict illustrative modalities for the treatment of seams where the plates are at an angle, for example, to form a wall corner. Corner angle reinforcement shavings can define and reinforce corner angles, provide continuity between the intersection of plasterboard planes and hide plasterboard corner seams when covered with compost. For example, to illustrate an outer corner, FIG. 4A depicts a wall mount 400 comprising a first plate 410 having a face 412. A second plate 420 has face 422. The plates 410 and 420 are at an angle to form a corner seam 424 adjacent a face edge 426 of the plate 410. The angle (x) is defined by the intersection of faces 412 and 422 in what is understood in the art as an external angle forming an external corner. The external angle can be any suitable angle depending on the wall configuration and dimensions as understood in the art. Normally, the angle (x) is a reflection angle as shown in FIG. 4A, that is, an angle exceeding 180 °, although smaller angles are possible in more exclusive corners. For example, in some embodiments, the angle (x) can be in a range, for example, from about 180 ° to about 300 °, including angles near 270 °, such as from about 230 ° to about 330 °, about 250 ° to about 310 °, about 260 ° to about 300 °, about 260 ° to about 280 °, about 265 ° to about 275 °, or about 268 ° to about 272 °.
[66] As can be seen in an exploded view of FIG. 4A, a reinforcement chip 428 is applied over the outer corner seam 424 and face edge 426 to cover and protect edge 426 and seam 424. Shaving 428 comprises a chip face 430 with reinforcement lining 432, which has a width which does not extend to the width of the chip face 430 in some embodiments. Adhesive 434 is used to apply chip 428 over outer corner seam 424 and face edge 426. Joint compound, including a one-layer joint compound in accordance with the modalities of the invention, is applied to the chip to hide the trim and the splice. After being applied and dried, the compost can be sanded and painted to provide a uniform aesthetic appearance.
[67] To illustrate an inner corner, FIG. 4B depicts a wall mount 450 comprising a first plate 452 having a face 454. A second plate 460 has face 462. The plates 452 and 460 are at an angle to form a corner seam 464. The angle (y) is defined by the intersection of faces 454 and 462 in what is understood in the art as an internal angle forming an internal corner. The internal angle can be any suitable angle depending on the wall configuration and dimensions as understood in the art. Typically, the angle (y) is an angle below 180 °, although larger angles are possible in more exclusive corners. For example, in some embodiments, the angle (y) can be in a range of, for example, about 30 ° to about 180 ° or about 45 ° to about 135 °, including angles close to 90 °, such as from about 60 ° to about 120 °, from about 70 ° to about 110 °, about 80 ° to about 100 °, about 85 ° to about 95 °, or about 88 ° to about 92 °.
[68] As can be seen in an exploded view of FIG. 4B, a reinforcement chip 466 is applied over the inner corner seam 464 to cover and protect the seam 464. Trim 466 comprises a chip face 468 with reinforcement lining 470, which has a width that does not extend as far as the width trim face 468 in some embodiments. Adhesive 472 is used to apply chip 466 to seam 464. Joint compound, including a one-layer joint compound in accordance with the modalities of the invention, is applied to the chip to hide the chip and seam. After being applied and dried, the compost can be sanded and painted to provide a uniform aesthetic appearance.
[69] The chip face 430 or 468 desirably comprises non-swollen paper (natural or synthetic) in some embodiments. Non-swelling paper is particularly desirable in one-layer systems since less compost will go over the paper and disguise any unwanted swelling that may lead to outstanding results or other misshapen results. For example, in some embodiments, face 430 or 468 has a dimensional stability of less than about 0.4% longitudinal expansion (MD) and less than about 2.5% longitudinal transverse expansion (CD) (for example , less than about 0.3% MD expansion and less than about 1.5% CD expansion, such as less than about 0.2% MD expansion and less than about 1% expansion of CD after 30 minutes immersion in water, ASTM C474-05, Section 12. It will be understood that the modalities that pass the test in relation to ASTM C474-05 may also exceed the minimum performance specifications established in ASTM C475 / C475M - 12 Standard Specification for Joint Compound and Joint Tape for Finishing Plasterboard.
[70] In some embodiments, face 430 or 468 has a thickness of about 0.01 inches (0.0254 cm) to about 0.125 inches (0.318 cm), such as about 0.05 inches (0.127 cm) ) at about 0.0625 (159 cm). It will be understood that the joint tape may be composed of the same materials, characteristics and properties, as the reinforcing chip face.
[71] The liner 432 or 470 for reinforcement chip 428 or 466 can comprise any suitable material that provides strength for the chip composite. The lining material is useful for reducing, controlling or eliminating the crack in the seam at the angles of the wall when the new construction frame moves and there is a small displacement of the wall. The lining material, together with the cladding material, also serves to form a true right-angled line along the vertex where two walls join or intersect at an angle. For example, chipboard liner 432 or 470 may comprise a laminated structure of composite, layered paper (synthetic or natural), thermoplastic, thermoset, natural or synthetic fiber, carbon fiber, polyester, polycarbonate, fiberglass, natural materials or non-woven synthetics, woven natural or synthetic materials, twisted polyolefin or metals such as steel, for example, electrogalvanized and / or hot-dip galvanized, treated with zinc phosphate and / or dried in a chromate sealer on site, and / or other treated or coated metals and the like. For example, in an illustrative embodiment, the liner 432 or 470 is formed of galvanized steel. The chip liner 432 or 470 desirably has any suitable thickness, for example, a thickness of at least about 0.010, for example, about 0.012 inches (0.030 cm) to about 0.0625 inches (0.159 cm), such as from about 0.012 inches to about 0.030 inches (0.0762 cm). In some liner material modalities, such as when galvanized steel is used, the liner typically imparts a Rockwell B hardness scale of about 45 to about 85, such as from about 55 to about 65, when measured from according to ASTM E18-03.
[72] Chip preparation is illustrated in modalities with non-swellable paper face with galvanized steel lining. The chips are prepared by running flat steel (on a spool) through a series of progressive molds and the coating material and metal lining are introduced right after the last set of molds. The lining and the lining can be glued to each other with hot glue in some embodiments. Another technique for forming reinforcement chips formed from a variety of materials will be apparent to one skilled in the art.
[73] FIGS. 5-18 are photographic images depicting several illustrative modalities of the invention. In particular, FIG. 5 shows a cut out of the board to reveal the panel adhesive applied to the frame. FIG. 6 depicts a room installation after painting. As can be seen in FIG. 6, a wall installation finished in accordance with the modalities of the invention can achieve a level 4 drywall finish with a layer of joint compound and without the need for multiple layers of joint compound as in conventional systems. In addition, FIG. 7 depicts the joint tape that was applied adhesively to the gypsum panel seams before the gypsum panels were treated with joint compound.
[74] Regarding the installation of internal and external corner, FIG. 8 depicts external corner shavings that are manufactured with non-swellable paper face with metallic lining. Meanwhile, FIG. 9 depicts an internal reinforcement trim with a non-swellable paper face and metal lining being pressed by hand in place. FIGS. 10-11 depict the application of trimming modalities of the invention using a roller. FIG. 12 depicts pieces of outer corner trim. FIG. 13 depicts a room installation with all internal and external shavings and flat joint tape installed. FIG. 14 depicts flat joint tape on the inner corner trim in the upper left corner of the image. The lower right corner of the image depicts a layer of joint compound applied to provide a level 4 drywall covering in accordance with the modalities of the invention.
[75] FIG. 15 depicts flat joint tape with a layer of joint compound applied to the left side of the image. It can be seen that a rear joint (transversal machine joint) without tapering was hidden by applying a layer of joint compound and then sanding. The right side of the image depicts the final painted aspect. FIG. 16 depicts a room installation with joint treatment installed while FIG. 17 depicts a finished wall cut to reveal the panel adhesive applied to the molding with tape and a joint treatment layer. In addition, FIG. 18 depicts a plasterboard with a conventional level 4 drywall finish with only a 12-inch wide dispersion in accordance with the modalities of the invention.
[76] In these and other embodiments, a joint compound composition in accordance with the present invention comprising (a) binder, (b) hollow spheres (sometimes referred to as bubbles) having an average isostatic crush resistance of at least about 100 psi (for example, at least about 250 psi), as measured according to ASTM D 3102-78 and optionally other ingredients. Preferably, the joint compound composition exhibits low shrinkage. For example, in some embodiments, the joint compound composition has a shrinkage of about 10% or less by volume, for example, about 7% or less, such as about 5% or less, about 2% or less, about 1% or less, about 0.1% or less or about zero (no contraction), as measured by ASTM C474-05, Section 6.
[77] The joint compound can have any suitable density, but preferably it is an ultra light composition having a density of about 10 lb / gal or less, such as about 8 lb / gal or less. For example, in some embodiments, the joint compound has a density from about 2 lb / gal (240 kg / m3) to about 8 lb / gal (960 kg / m3) (preferably from about 2 lb) / gal to about 6 lb / gal (720 kg / m3), more preferably about 3 lb / gal (360 kg / m3) to about 4 lb / gal (480 kg / m3)).
[78] Generally, the composition is a drying-type joint compound, in which the compound hardens by evaporation of water. Thus, in some embodiments, the joint compound composition is substantially free of fixing type materials such as calcined plaster, cement or other hydraulic fixing materials. In addition, in some embodiments, the joint compound composition may desirably be substantially free of raw materials such as bulk filler, clays, starch or mica; including such examples as calcium carbonate, expanded perlite, calcium magnesium carbonate, limestone, calcium sulfate dihydrate, a gelling clay such as attapulgite clay, a delaminated clay, such as kaolin clay, talc and diatomaceous earth. In addition, the joint compound composition can desirably be substantially free of any combination of the raw materials mentioned above.
[79] As used in this document, "substantially free" of such handle minerals, filler by mass, clays, starch, mica or a combination thereof means that the joint compound composition contains any (i) 0% by weight based in the weight of the composition, or none of these handle minerals, filler in bulk, clays, starch, mica, or a combination thereof, or (ii) an ineffective amount or (iii) an immaterial amount of such handle minerals, filler in mass , clays, starch, mica or a combination thereof. An example of an ineffective amount is an amount below the threshold amount to achieve the intended purpose of using such handle minerals, bulk fillers, clays, starch, mica or a combination thereof as a person ordinarily skilled in the art will appreciate. An immaterial amount can be, for example, below about 5% by weight, such as below about 2% by weight, below about 1% by weight, below about 0.5% by weight, below of about 0.2% by weight, below about 0.1% by weight, or below about 0.01% by weight as a person ordinarily skilled in the art will appreciate. However, if desired in alternative embodiments, such ingredients can be included in the composition of the joint compound.
[80] In alternative modalities, bulk filler (eg calcium carbonate or limestone) or delaminated clay, such as kaolin clay, may be present. These raw materials can be added, in some modalities, to adapt the joint compound to the subjective sensation desired by the end user during the application process. These raw materials, as used in this document, do not otherwise alter the physical properties of the joint compound. In such embodiments, up to about 40% by weight of filler by mass, such as calcium carbonate or limestone, can be included. If included, in some embodiments, the bulk filler can be present, for example, in an amount of up to about 35% by weight, up to about 30% by weight, up to about 25% by weight, up to about 20 % by weight, up to about 15% by weight, up to about 10% by weight, up to about 5% by weight, or up to about 1% by weight added based on the weight of the wet composition. Each of the above end points may have a lower limit, for example, ranging from 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight or 35% by weight, as numerically appropriate.
[81] For example, in various embodiments, the bulk filler can be present from about 1% by weight to about 40% by weight, for example, from about 1% by weight to about 30 % by weight, from about 1% by weight to about 25% by weight, from about 1% by weight to about 20% by weight, from about 1% by weight to about 15% by weight, from about 1% by weight to about 10% by weight, from about 5% by weight to about 30% by weight, from about 5% by weight to about from 25% by weight, from about 5% by weight to about 20% by weight, from about 5% by weight to about 15% by weight, from about 5% by weight to about 10% by weight, from about 10% by weight to about 30% by weight, from about 10% by weight to about 25% by weight, from about 10% by weight to about 20% by weight, from about 15% by weight to about 30% by weight, from about 15% by weight to 25% by weight, or ranging from about 20% by weight to about 30% by weight.
[82] If included, delaminated clay, such as kaolin clay, can be present in some embodiments, for example, in an amount up to about 5% by weight, up to about 4.5% by weight, up to about 4% by weight, up to about 3.5% by weight, up to about 3% by weight, up to about 2.5% by weight, up to about 2% by weight, up to about 1.5% by weight , up to about 1% by weight, about 0.5% by weight, or up to about 0.1% by weight added based on the weight of the wet composition. Each of the above end points can have a lower limit, for example, ranging from 0.1% by weight, 0.5% by weight, 1% by weight, 1.5% by weight, 2% by weight, 2 , 5% by weight, 3% by weight, 3.5% by weight, 4% by weight or 4.5% by weight, as numerically appropriate.
[83] For example, in several embodiments, delaminated clay, such as kaolin clay, can be present from about 0.1% by weight to about 5% by weight, for example, from about 0.1% by weight to about 4% by weight, from about 0.1% by weight to about 3% by weight, from about 0.1% by weight to about 2% by weight weight, from about 0.1% by weight to about 1% by weight, from about 0.1% by weight to about 0.5% by weight, from about 0.5 % by weight to about 5% by weight, from about 0.5% by weight to about 4% by weight, from about 0.5% by weight to about 3% by weight, at from about 0.5% by weight to about 2% by weight, from about 0.5% by weight to about 1% by weight, from about 1% by weight to about 5 % by weight, from about 1% by weight to about 4% by weight, from about 1% by weight to about 3% by weight, from about 1% by weight to about 2% by weight, from about 2% by weight about 5% by weight, from about 2% by weight to about 4% by weight, from about 2% by weight to about 3% by weight, from about 3% by weight to about 5% by weight, from about 3% by weight to about 4% by weight or from about 4% by weight to about 5% by weight.
[84] Any suitable binder can be used to achieve the desired joint compound in accordance with aspects of the invention. Desired binders hold particles in the composition together and form a film. In some embodiments, the binder is selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and their combinations. The binder in some embodiments has a glass transition temperature (Tg) from about 32 ° F (0 ° C) to about 70 ° F (21 ° C), for example, about 32 ° F to about 66 ° F (18 ° C), such as from about 40 ° F (5 ° C) to about 60 ° F (15 ° C), for example, about 55 ° F (13 ° C). In some embodiments, the binder has a minimum film-forming temperature (MMFT) from about 32 ° F to about 90 ° F (32 ° C), for example, from about 32 ° F to about 86 ° F (30 ° C), such as from about 40 ° F (5 ° C) to about 60 ° F (15 ° C), for example, about 52 ° F (11 ° C) .
[85] In some embodiments, the binder can generally be any suitable film-forming resin (or combinations thereof) capable of forming a solid film and bonding solid materials to the surface to which the joint compound composition is applied. For example, the binder can be an acrylic acid polymer and / or acrylic acid copolymer in some embodiments. The binder is in the form of an aqueous emulsion in some embodiments, with suitable latex emulsion medium including, but not limited to, acrylics, such as, for example, vinyl acrylics and styrene acrylics. In some embodiments, suitable binder materials include acrylic latex, vinyl-acrylic, vinyl acetate, polyurethane, and / or combinations thereof.
[86] Useful latex emulsion media include polyacrylate ester polymers marketed under the trade names RHOPLEX® (Rohm & Haas), acrylic polymers, acrylic vinyl polymers, eg vinyl acetate copolymers - butyl acrylates, polymers acrylic styrene, and vinyl acetate polymers marketed under the trade names UCAR ™ and NEOCAR ™ (The Dow Chemical Company, Michigan) such as UCAR ™ 367; emulsion polymer products marketed under the trade name VINREZ® (Halltech, Inc., Ontario); acrylic vinyl polymers marketed under the trade name Plioway® (Eliokem, Ohio); acrylic, acrylic vinyl and acrylic styrene latex polymers marketed under the trade name AQUAMAC ™ (ResolutionSpecialty Materials, LLC, Illinois); and acrylic vinyl resin marketed under the trade name VINREZ® 663 V15 (Halltech, Inc., Ontario), which has a glass temperature of around 18 ° C. Another acrylic vinyl copolymer binder is marketed under product identification No. HP-31-496 (Halltech, Inc., Ontario), and has a glass temperature of about 0 ° C.
[87] Suitable alkyd acrylics, polyurethanes, polyesters and functionalized epoxies can be obtained from a number of commercial sources. Useful acrylics are sold under the trade name ACRYLOID ™ (Rohm & Haas, co., Pennsylvania); useful epoxy resins are sold under the trade name EPON ™ (Resolution Specialty Materials, LLC, Illinois); useful polyester resins are sold under the trade name CYPLEX® (Cytec Industries, New Jersey); and useful vinyl resins are sold under the trade name UCAR ™ (The Dow Chemical Company, Michigan).
[88] The binder can be included in the composition of the joint compound in any suitable amount. For example, the binder can be included in an amount from about 5% by weight to about 100% by weight (on a solids basis) of the wet composition, such as from about 20% by weight at about 80% by weight, from 30% by weight to about 70% by weight, from about 40% by weight to about 60% by weight, etc.
[89] Hollow spheres contain self-contained air connected by a solid barrier. Since the air is contained within a solid casing, the air does not agglutinate in such a way that, in general, the air can be distributed throughout the compound and maintain a substantially uniform density. The hollow spheres facilitate a lower density, but desirably have good strength properties, in such a way that the hollow spheres transmit crushing resistance to them, in such a way that the dry joint compound, after application, is substantially non-brittle, in some modalities, in contrast to the conventional joint compound, which is brittle and fragile.
[90] Spheres in some embodiments facilitate an ultralight joint compound, which results in desired properties and creates less stress on a user when lifting compound in buckets, etc. during a working day. The beads can have any suitable density, such as a density from about 0.0015 lb / in3 to about 0.04 lb / in3, for example, about 0.0018 lb / in3 (0.05 g / cm3) to about 0.036 lb / in3 (1 g / cm3), such as from about 0.0036 lb / in3 (0.1 g / cm3) to about 0.0253 lb / in3 (0.7 g / cm3). With regard to strength, for example, the balls can have an average isostatic crush resistance of at least about 50 psi (340 kPa), measured according to ASTM D 3102-78, as well as an isostatic crush resistance of at least about 100 psi (690 kPa). For example, the isostatic force of the balls can be from about 50 psi to about 50,000 psi (344,740 kPa), from about 50 psi to about 25,000 psi (172,000 kPa), from about 50 psi to about 10,000 psi , from about 50 psi to about 5,000 psi (34,000 kPa), from about 50 psi to about 1,000 psi, from about 50 psi to about 500 psi (3,450 kPa), from about 100 psi to about 50,000 psi, from about 100 psi to about 25,000 psi, from about 100 psi to about 10,000 psi, from about 100 psi to about 5,000 psi, from about 100 psi to about 1,000 psi, from about 100 psi to about 500 psi, from about 250 psi (1,720 kPa) to about 50,000 psi, from about 250 psi to about 25,000 psi, from about 250 psi to about 10,000 psi, from about 250 psi to about 5,000 psi, from about 250 psi to about 1,000 psi, from about 250 psi to about 500 psi, from about 500 psi to about 50,000 psi, from about 500 psi to about 25,000 psi, from about 500 psi to about 10,000 p itself, from about 500 psi to about 5,000 psi, from about 500 psi to about 1,000 psi, from about 1,000 psi to about 50,000 psi, from about 1,000 psi to about 25,000 psi, from about 1,000 psi to about 10,000 psi, from about 1,000 psi to about 5,000 psi, from about 2,500 psi (17200 kPa) to about 50,000 psi, from about 2,500 psi to about 25,000 psi, from about 2,500 psi to about 10,000 psi, from about 2,500 psi to about 5,000 psi, etc.
[91] Examples of types of spheres in accordance with the modalities of the invention include borosilicate lime, polystyrene, ceramics, recycled glass, expanded glass and light polyolefin granules, and / or any other chemical form of plastic. For example, in some embodiments, spheres for use in the joint compound include but are not limited to borosilicate-lime-soda glass bubbles (for example, as marketed under the trade name Scotchlite ™ (3M)), hollow glass microspheres multicellular (for example, as marketed under the trade name Omega-Bubbles ™ (Omega Minerals)), expandable polymeric microspheres (for example, as marketed under the trade name DUALITE® (Henkel)), polyolefin microgranules and polystyrene microspheres ( for example, as marketed under the trade name Spex <ite® (Schabel PolymerTechnology, LLC)), expanded glass beads (for example, as marketed under the trade name Poraver®, North America) and combinations thereof. As illustrative embodiments, suitable spheres can comprise K1 and / or K15 Scotchlite ™ (3M).
[92] The spheres can have any suitable diameter and can be supplied in any suitable concentration. It will be understood that the term spheres is known in the art and does not imply a perfectly geometric sphere, as the spheres may have irregular shapes. Thus, the diameter as used in this document refers to the diameter of the smallest geometric sphere that encompasses the real sphere. In some embodiments, the beads can have a diameter of about 10 microns to about 100 microns, such as from about 40 microns to about 80 microns or from about 50 microns to about 70 microns. With regard to quantities, in some embodiments, the spheres are present in an amount of about 2% to about 50% by weight of the wet composition, such as, for example, from about 5% to about 35% , from about 7% to about 25% or from about 10% to about 20%.
[93] In some embodiments, the composition of the joint compound optionally also includes surfactant. Desirably, the surfactant can facilitate stabilization of the binder so that the binder does not flocculate. Surfactant desirably can also provide a wet or dispersing action. In this regard, when dry raw materials are added to the water, the dry materials can compete for water and form unwanted clumps. Thus, in some embodiments, the surfactant is included to increase the ease of mixing by incorporating dry materials in liquid and additionally assists in pumping the joint compound from filling stations and in buckets during manufacture. The surfactant is also beneficial during use, when applying the joint compound, for example, with distribution tools known in the art.
[94] For example, in some embodiments, the surfactant may be a nonionic surfactant having a hydrophilic-lipophilic balance (HLB) of about 3 to about 20, such as about 4 to about 15 or about 5 to about 10. It will be understood that surfactants with HLB values below 9 are generally considered to be lipophilic, those with values between 11 and 20 are generally considered to be hydrophilic, and those with values between 9 and 11 are generally considered to be intermediates. Suitable non-ionic surfactants having an HLB value below about 9 include, but are not limited to, ethoxylated octylphenol and ethoxylated nonylphenol, including non-ionic surfactants having below 9 HLB values marketed under the trade names TRITON ™ and TERGITOL ™ ( The Dow Chemical Company, Michigan). Suitable nonionic surfactants having an HLB value greater than about 11 include ethoxylated octylphenol and ethoxylated nonylphenol which have more ethylene oxide units than nonionic surfactants having an HLB value below about 9. Useful surfactants having higher HLB values than about 11 are also marketed under the trade name TRITON ™ (The Dow Chemical Company, Michigan). Other surfactants can also be used as long as the HLB value for (mixture of) surfactant (s) is as previously described for joint compound compositions and combinations thereof. If included, the nonionic surfactant can be present in any suitable amount, such as from about 0.001% to about 15% by weight of the wet composition, such as from about 0.001% to about 10%, from about 0.001 % to about 5%, or about 0.01% to about 0.5%.
[95] One or more defoamer, such as, for example, petroleum distillate or the like, as known in the art, is optionally included in some embodiments of the joint compound composition. If included, the defoamer can be present in an amount from about 0.01% to about 15% by weight of the wet composition, such as from about 0.05% to about 5% or from from about 0.3% to about 1%.
[96] Humectant is optionally included in some modalities. For example, humectants can be used to help keep the joint compound moist by facilitating moisture retention and can also help with the use of mechanical distribution tools. In particular, one or more humectants is included in aqueous joint compound composition modalities in order to delay drying of the joint compound composition and provides a more consistent finish. Humectants can also advantageously provide defrost-freeze tolerance and / or stability in the composition of the joint compound. Any suitable humectants can be included, such as, for example, sorbitol derivatives, polyhydric alcohols, including but not limited to glycols such as ethylene glycol, diethylene glycol (DEG), triethylene glycol, propylene glycol, dipropylene glycol, and / or tripropylene glycol or any combination of these. If included, humectants can be present in an amount from about 0.001% to about 15% by weight of the wet composition, such as from about 0.001% to about 10%, from about 0.01% to about 5%, or about 0.001% to about 3%.
[97] Optionally, the joint compound composition comprises a rheological modifier in some embodiments. If included, the rheological modifier is generally provided to improve certain rheological properties such as flow, viscosity, application properties, and other performance attributes associated with joint compounds. For example, in some embodiments, rheological modifiers are often added to provide layer compositions with desired viscosity values as described in this document, for example, using C.W. Brabender visco-corder equipment to measure the viscosity of the joint compound composition.
[98] Rheological modifiers suitable for optional use of the joint compound composition include, but are not limited to, cellulosic and associative thickeners, including but not limited to, hydrophobically modified ethoxylated urethanes (HEUR), hydrophobically modified soluble alkali emulsions (HASE) and styrene-maleic anhydride (SMAT) terpolymers, and / or combinations thereof. Exemplary cellulosic rheological modifiers include, but are not limited to, cellulose ethers such as hydroxyethyl cellulose (HEC), ethylhydroxyethyl cellulose (EHEC), methylhydroxyethyl cellulose (MHEC), carboxymethylcellulose (CMC), hydroxypropylmethyl cellulose (HPMC), and / or others cellulose ethers having a molecular weight between 1000 and 500,000 daltons, for example hydroxypropyl alkyl cellulose ethers, hydroxypropyl methyl celluloses, as well as xanthan gums, sodium alginates and other salts of alginic acid, carrageenans, gum arabic ( mixed salts of arabic acid), karaya gum (an acetylated polysaccharide), tragacanth gum (a complex mixture of acidic polysaccharides), ghatti gum (the calcium and magnesium salt of a complex polysaccharide), guar gum (a straight chain galactomannan ) and its derivatives, algarrobo gum (a branched galactomannan), tamarind gum, psyllium seed gum, quince seed gum, larch gum, pectin and its derivatives, dextrans and hydroxypropylcelluloses or any combination thereof.
[99] If included, the rheological modifier can be included in any suitable amount, for example, to achieve a desired viscosity as will be appreciated by a person ordinarily skilled in the art. For example, in some embodiments, the rheological modifier is included in an amount of about 0.01% to about 15%, by weight of the wet composition, such as from about 0.01% to about 10%, from about 0.1% to about 5%, from about 0.1% to about 3%, from about 0.1% to about 2% or from about 0.1% to about 1% . The joint compound typically comprises from about 0.01% by weight to about 10% by weight, about 0.1% by weight to about 5.0% by weight, and / or about 0.10% by weight to about 3.0% by weight of the cellulosic thickener. The alkyl group of useful hydroxypropyl alkyl celluloses can contain up to 9 carbon atoms, but generally the alkyl group contains from one to three atoms. Hydroxypropyl methyl celluloses having an average of about two hydroxypropyl and / or methoxypropyl groups per anhydroglucose unit are often used. The viscosity of an aqueous solution containing about 2% by weight of a suitable hydroxypropyl alkyl cellulose ether at 20 ° C is about 60,000 centipoises (cps) at about 90,000 cps, as measured with a Ubbelohde tube capillary viscometer. . Alternatively, similar measurements can be made with a Brookfield viscometer at a speed between about 2.5 rpm and 5 rpm. In a refinement, the initially solid color layer composition contains about 0.25% by weight of a hydroxypropyl alkyl cellulose ether. Of course, other types of cellulosic thickeners can also be used, and a larger amount may be required if a lower viscosity thickener is used (or vice versa). Exemplary hydroxypropyl alkyl cellulose ethers are marketed under the trade name Methocel® (The Dow Chemical Company, Michigan).
[100] Associative thickeners suitable for optional use in joint compound compositions include hydrophobically modified ethoxylated urethanes (HEUR), hydrophobically modified soluble alkali emulsions (HASE) and styrene-maleic anhydride (SMAT) terpolymers. HEUR thickeners (generally also known as polyurethane or PUR associative thickeners) can be included in the latex-based aqueous joint compound and other yielding solid / liquid-like compositions. Copolymers of acidic acrylate (crosslinked) of ethyl acrylate and methacrylic acid and terpolymers (crosslinked) of ethyl acrylate, methacrylic acid, non-ionic urethane surfactant monomer can also be optionally used as associative thickeners. When one or more suitable associative thickeners are used, the thickening reaction is caused in part by association with another thickener molecule or any association between the associative thickener and at least one other particle of the joint compound composition (for example, a particle pigment or resin particle) or other associative thickener molecule. In several embodiments, if included, the joint compound composition may comprise from about 0.01% by weight to about 10% by weight, about 0.1% by weight to about 5.0% by weight, and / or about 0.1% by weight to about 3% by weight of the associative thickener. Useful associative thickeners include those marketed under the trade name Alcogum® (Alco Chemical Company, TN), the trade name Acrysol® (Rohm & Haas, PA) and the trade name Viscalex® (Ciba Specialty Chemicals, NY).
[101] In an illustrative embodiment, the rheological modifier comprises a HEUR and a cellulose ether, for example, a hydroxypropyl alkyl cellulose ether. Without the intention of being bound by any particular theory, it is believed that the combination of an associative thickener and a cellulose ether provides improved application and storage properties. For example, the lubrication and flow characteristic of joint compound compositions (when applied to a substrate) can be improved by using such a combination of associative thickener and cellulose ether. In addition, such a combination can help prevent beads from the joint compound compositions from settling (when the joint compound compositions are stored in bulk).
[102] The rheologically modified associative thickener system generally performs best under alkaline conditions. Thus, it is generally advisable to include a basic material in the joint compound composition to give the final joint compound composition a pH of at least about 8.0. A variety of basic materials can be used to increase the pH, including but not limited to ammonia, lye (sodium hydroxide), tri-ethylamine (TEA) and 2-amino-2-methyl-1 propanol (AMP). In several embodiments, the joint compound composition comprises about 0.001% by weight to about 10% by weight, about 0.01% by weight to about 0.5% by weight, and / or about 0, 01% by weight to about 0.50% by weight of the alkaline / basic material.
[103] In some embodiments, the joint compound composition optionally comprises biocide in any suitable amount, for example, from about 0% to about 3% by weight of the wet composition, such as from about 0.05% to about from 2%, from about 0.1% to about 1.5% or from about 0.1% to about 1%. If included, in some embodiments of the joint compound composition, the biocide comprises a bactericide and / or a fungicide. An illustrative useful bactericide is marketed under the trade name MERGAL 174® (TROY Chemical Corporation). An illustrative useful fungicide is marketed under the trade name FUNGITROL® (International Specialty Products, New Jersey), or any combination thereof.
[104] The joint compound composition can be formulated to have any suitable viscosity to allow for workability as will be understood in the art. For example, the viscosity of the joint compound composition when wet can have a viscosity of about 100 units of Brabender (BU) to about 700 BU, such as from about 100 BU to about 600 BU, about 100 BU about 500 BU, about 100 BU to about 400 BU, about 100 BU to about 300 BU, about 100 BU to about 200 BU, about 130 BU to about 700 BU, about 130 BU about 600 BU, about 130 BU to about 500 BU, about 130 BU to about 400 BU, about 130 BU to about 300 BU, about 130 BU to about 200 BU, about 150 BU about 700 BU, about 150 BU to about 600 BU, about 150 BU to about 500 BU, about 150 BU to about 400 BU, about 150 BU to about 300 BU, or about 150 BU to about 200 BU. A person ordinarily versed in the technique will easily recognize Brabender units. Viscosity is measured according to ASTM C474-05, Section 5 using a CW Brabender viscometer with a Type A pin, 1/2 pint sample cup size with a 250 cm-gm Brabender Torque-Head cartridge and an RPM of 75.
[105] Desirably, in some embodiments, to improve the anti-contraction property of the joint compound composition, water content is desirably reduced compared to conventional formulations. It will be understood that some raw materials (for example, latex emulsions and the like) are provided in an aqueous form. However, additional water (for example, kneading water) is desirably kept low in some embodiments, for example, in an amount of about 60% or less by weight of the wet composition, for example, from about 0% to about 50%, such as from about 0% to about 30%, from about 0% to about 15% or from about 0% to about 10%, etc. In some embodiments, the total water content of the joint compound, including water from another raw material including latex emulsion binder and any kneading water, can vary, for example, from about 5% to about 60% in weight of the wet composition, such as from about 10% to about 45% by weight, or about 25% to about 45% by weight, or more.
[106] In some embodiments, the invention provides a joint compound composition consisting essentially of (a) latex emulsion binder in an amount of about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow spheres having an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78, wherein the spheres are present in an amount of about 5% to about 25% by weight of the wet composition; (c) nonionic surfactant in an amount of about 0.001% to about 5% by weight of the wet composition; and (d) wetting in an amount of about 0.001% to about 3% by weight of the wet composition; and, optionally, (e) defoamer in an amount of about 0.05% to about 5% by weight of the wet composition; (f) rheological modifier in an amount of about 0.1% to about 5% by weight of the wet composition; (g) biocide, in an amount of about 0.1% to about 1.5% by weight of the wet composition; (h) bulk filler, such as calcium carbonate or limestone, in an amount of about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of about 0.1% to about 5% by weight of the wet composition. In such embodiments, the composition excludes any raw material other than the aforementioned ingredients that materially affects the composition of the inventive joint compound.
[107] Modalities of the invention also provide a wall mount in accordance with the various aspects described in this document. The wall mount comprises two adjacent plates, joined by a splice. In some embodiments, only one layer of the joint compound is applied over the splice to provide a uniform aesthetic appearance. However, if desired, more than one layer (for example, two or three layers) can be applied depending on the desired finish level. The joint compound composition comprises binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof. The composition also comprises a plurality of hollow spheres. The balls desirably have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78. The wall mount additionally comprises a flat, non-expandable, dimensionally stable joint tape incorporated into the seam.
[108] Modalities of the invention also provide a method of treating a drywall assembly of two adjacent boards joined by a splice in accordance with the various aspects described in this document. In some embodiments, the method comprises applying joint tape and a layer of the joint compound composition to the splice. The joint compound composition comprises binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof. The composition also comprises a plurality of hollow spheres. The balls desirably have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78. The method further comprises drying the composition. In some embodiments, after the joint compound is applied and dried, the drywall assembly can be sanded and / or painted to give a desired visual appearance.
[109] The following modalities further illustrate aspects of the invention, but, of course, should not be construed in any way as limiting its scope.
[110] In one embodiment, a drying-type joint compound composition comprises, a binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof; and a plurality of hollow spheres, in which the spheres have an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78.
[111] In another embodiment of the joint compound composition, the binder is an acrylic acid polymer or acrylic acid copolymer.
[112] In another embodiment of the joint compound composition, the binder is in the form of an aqueous emulsion.
[113] In another embodiment of the joint compound composition, the composition has a density of about 2 lb / gal to about 8 lb / gal.
[114] In another embodiment of the joint compound composition, the composition exhibits a contraction of about 2% or less, as measured by ASTM C474-05.
[115] In another embodiment of the joint compound composition, the composition is substantially free of handle minerals, filler by mass, clays, starch, mica or a combination thereof.
[116] In another embodiment of the joint compound composition, the composition is substantially free of calcium carbonate, expanded perlite, calcium and magnesium carbonate, limestone, dihydrated calcium sulfate, delaminated clay, such as kaolin clay, talc, diatomaceous earth or a combination of these.
[117] In one embodiment of the joint compound composition, the composition is substantially free of gelling clays. Such gelling clays include attapulgites, sepiolites, bentonites, laponites, nontronites, beidelites, laponites, yakhontovites, zincsilites, volkonskoites, hectorites, saponites, ferrousaponites, sauconites, swinefordit, pimelites, sobockitas, stevensites, stevensites, stevensites, stevensites, stevensites, stevensites, stevensites, steviteites, smectites, for example, montmorillonites, particularly sodium montmorillonite, magnesium montmorillonite and calcium montmorillonite, illites, mixed layered Ilita / smectic minerals such as rectorites, tarosovites and ledikites, magnesium aluminum silicates and mixtures of the above-named clays. Paligorsquite attapulgite clays are a type of illustrative gelling clay that are excluded in this modality.
[118] In another embodiment of the joint compound composition, the binder has a glass transition temperature (Tg) of about 32 ° F (0 ° C) to about 70 ° F (21.1 ° C).
[119] In another embodiment of the joint compound composition, the binder has a minimum film-forming temperature (MMFT) of about 32 ° F (0 ° C) to about 90 ° F (32.2 ° C) .
[120] In another embodiment of the joint compound composition, the beads have an isostatic crush resistance of at least about 250 psi.
[121] In another embodiment of the joint compound composition, the spheres have a density of about 0.0015 lb / in3 to about 0.04 lb / in3.
[122] In another embodiment of the joint compound composition, the spheres comprise lime borosilicate, polystyrene, ceramics, recycled glass, expanded glass and granules of light polyolefin, thermoplastic, thermoset or any combination thereof.
[123] In another embodiment of the joint compound composition, the composition additionally comprises a nonionic surfactant having a hydrophilic-lipophilic balance (HLB) of about 3 to about 20.
[124] In another embodiment of a joint compound composition consisting essentially of: (a) latex emulsion binder in an amount of about 3% to about 90% by weight of the wet composition; (b) a plurality of hollow spheres having an average isostatic crush resistance of at least about 100 psi, as measured according to ASTM D3102-78, in which the spheres are present in an amount of about 5% to about 25% by weight of the wet composition; (c) nonionic surfactant in an amount of about 0.001% to about 5% by weight of the wet composition; and (d) wetting in an amount of about 0.001% to about 3% by weight of the wet composition; and, optionally: (e) defoamer in an amount of about 0.05% to about 5% by weight of the wet composition; (f) rheological modifier in an amount of about 0.1% to about 5% by weight of the wet composition; (g) biocide, in an amount of about 0.1% to about 1.5% by weight of the wet composition; (h) bulk filler, such as calcium carbonate or limestone, in an amount of about 1% to about 40% by weight of the wet composition; and (i) delaminated clay, such as kaolin clay, in an amount of about 0.1% to about 5% by weight of the wet composition.
[125] In another embodiment, a wall mount comprises: (a) two adjacent plates, joined by a splice; (b) only one layer of the joint compound composition according to claim 1 in the seam to provide a uniform aesthetic appearance; and (c) flat, non-expandable, dimensionally stable joint tape incorporated into the splice.
[126] In another embodiment of the wall mount, at least one plate has a tapered edge adjacent to the seam, the tapered edge having a maximum depth of about 0.125 inches (about 0.3 cm) or less.
[127] In another modality of wall mounting, the plates comprise opposite front and rear surfaces, in which the faces of two adjacent plates are arranged in relation to each other to define an inner corner with a corner angle between the faces of the plate from about 30 ° to about 180 °.
[128] In another modality of wall mounting, the plates comprise opposite front and rear surfaces, the faces of two adjacent plates are arranged in relation to each other to define an external corner with an angle between the faces of the plate of about 180 ° to about 300 °.
[129] In another modality of wall mounting, mounting additionally comprises reinforcement chip disposed on the seam, in which the chip comprises (i) a coating material comprising paper having a dimensional stability less than about 0.4% of longitudinal expansion and less than about 2.5% transverse expansion after immersion of 30 minutes in water, as measured according to ASTM C474-05, Section 12 and (ii) a reinforcement liner comprising paper, plastic, natural fiber or synthetic, carbon fiber, polyester, polycarbonate, fiberglass, natural or synthetic non-woven materials, natural or synthetic woven materials, twisted polyolefin, or metal, where the lining has a thickness of about 0.012 inches (about 0 , 03 cm) to about 0.0625 inches (about 0.2 cm).
[130] In another modality of wall mounting, the mounting comprises adhesive to at least partially affix the reinforcement trim to the edges of the board.
[131] In another embodiment of the wall mount, the mount additionally comprises at least one molding and adhesive member, the adhesive at least partially affixing at least one plate to the molding member.
[132] In another embodiment, a method of treating a drywall assembly of two adjacent boards, joined by a splice, is presented. The method comprises (a) applying joint tape and a layer of the joint compound composition according to claim 1 in the amendment; and (b) drying the composition.
[133] In another embodiment, a reinforcement chip is provided to protect a splice of two adjacent plates having opposite front and rear surfaces, the faces being arranged at an angle between the faces of the plate, the chip comprising: a paper face characterized by a non-expandable synthetic paper covering material; and a reinforcement lining comprising paper, thermoplastic, thermoset, natural or synthetic fiber, carbon fiber, polyester, polycarbonate, fiberglass, natural or synthetic non-woven materials, natural or synthetic woven materials, twisted polyolefin or metal, in which the lining has a thickness of about 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0.2 cm).
[134] In another embodiment of a drying type joint compound composition, it comprises a binder selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxy and combinations thereof; and a plurality of hollow spheres, in which the spheres have an average isostatic crush resistance of at least about 250 psi, as measured according to ASTM D3102-78; and in which the density of the beads are from about 0.0015 lb / in3 (about 0.04 g / cm3) to about 0.04 lb / in3 (about 1.1 g / cm3).
[135] In another embodiment of the joint compound composition, the beads have an isostatic crush resistance of at least about 500 psi.
[136] In another embodiment of the joint compound composition, the spheres have a density of about 0.0018 lb / in3 (0.05 g / cm3) to about 0.036 lb / in3 (1 g / cm3).
[137] In another embodiment of the joint compound composition, on a 3/16 inch (about 0.5 cm) strip, at least 60% water content is removed by drying within about 1.5 to 4.5 hours in a moderate environment of about 75 ° F (about 24 ° C) and about 50% relative humidity.
[138] In another embodiment of the joint compound composition, on a 3/16 inch (about 0.5 cm) strip, at least 60% water content is removed within about 1 to about 3 hours in a hot, dry environment of about 95 ° F (about 35 ° C) and approximately 10% relative humidity.
[139] In another embodiment of the joint compound composition, on a 3/16 inch (about 0.5 cm) strip, at least 60% water content is removed by drying within about 5 to about 12.5 hours in a cold, humid environment of about 40 ° F (about 4 ° C) and about 80% relative humidity.
[140] In another embodiment of the joint compound composition, on a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed by drying within about 0.5 to 2 hours in a moderate environment of about 75 ° F (about 24 ° C) and about 50% relative humidity.
[141] In another embodiment of the joint compound composition, on a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed within about 1 hour in a warm environment and dry at about 95 ° F (about 35 ° C) and about 10% relative humidity.
[142] In another embodiment of the joint compound composition, on a 1/16 inch (about 0.2 cm) strip, at least 60% of the water content is removed within about 0.5 to about 3 hours in a cold, humid environment of about 40 ° F (about 4 ° C) and about 80% relative humidity.
[143] The following examples further illustrate the invention but, of course, should not be interpreted as some way of limiting its scope. EXAMPLE 1
[144] This example establishes three sample formulations (1A, 1B and 1C) illustrating joint compound in accordance with the modalities of the invention.
[145] As an illustrative method of preparation, all liquid ingredients were added to a Hobart model N50 mixer. In this regard, it is to be noted that the functional filler (Scotchlite K1) and rheological polymer (Cellosize DSC) were the only dry materials with the remainder considered in liquid form for the purpose of addition to the mixer. Since the functional filler was in bulk and the rheological polymer was in small quantity, the rheological polymer was added to the functional filler, and the combined dry material was added to the mixer with the liquids already included. The resulting composition was mixed for approximately 2 minutes until uniform.
[146] However, it will be understood that formulations can be prepared in any suitable manner. For example, the composition can be prepared on a plant scale in the horizontal cable mixer with helical blade configuration or the like to promote proper mixing dynamics as will be understood by a person ordinarily skilled in the art.
[147] Formulation 1A is set out in Table 1 below. It will be understood that "added water" refers to additional water that is not yet present in any of the ingredients (for example, RHOPLEX is in the form of a water / solids emulsion 47/53 by weight). Table 1


[148] Formulation 1B is set out in Table 2 to Table 2 below.

[149] Formulation 1C is set out in Table 3 below. Table 3


[150] The formulations set out in Table 1 include relatively low amounts of water and result in low levels of contraction while also exhibiting good compressive strength and flexural strength. They can be easily applied with fewer layers than applied in conventional systems (for example, desirably in a layer application system) to seams, chips and fasteners in wall mountings in accordance with some embodiments of the invention. As a result, Formulations 1A - 1C allow efficient application without considerable delays that require downtime as each separate layer dries. Formulations 1A - 1C also allow easy application, requiring less skill on the part of the user, since formulations can be applied closer to the plane of the wall mounts. Formulations 1A - 1C exhibited shrinkage from about zero to about 3%, as measured according to ASTM C474-05, Section 6. In addition, Formulations 1A - 1C were crack resistant when measured according to ASTM C474-05 , Section 7. EXAMPLE 2
[151] This example illustrates the superior strength properties exhibited by joint compound in accordance with embodiments of the invention compared to two different conventional joint compounds.
[152] A total of three specimens were tested for flexural strength. Each specimen of joint compound was formed and dried on a strip having a length of 10 inches, a width of 2 inches (about 5 cm) and a thickness of 0.0625 inches (about 0.2 cm). Each specimen was placed on a table with its extremities at rest in thick spacers of 0.125 (1/8) inch (about 0.3 cm) in order to demonstrate that, with the smallest displacement, the fragile nature and friability associated with representative samples of commercially available joint compound product formulations used in industry. A downward force of about 200 gm was applied to the center of each joint compound strip with a metal probe.
[153] For comparison, the first specimen, Formulation 2A, was a conventional joint compound commercially available as USG SHEETROCK® All Purpose Joint Compound which has a density of approximately 14 lb / gal. The progression of the test is shown in FIGS. 19-21. As can be seen in FIG. 21, the joint compound broke with less than 1/8 inch of deflection, thereby showing the fragile nature of the specimen.
[154] For comparison purposes, the second specimen, Formulation 2B, was a conventional joint compound commercially available as USG SHEETROCK® All Purpose Joint Compound which has a density of approximately 8 lb / gal. The progression of the test is shown in FIGS. 22-24. As can be seen in FIG. 24, the joint compound broke with less than 1/8 inch of deflection, thereby showing the fragile nature of the specimen.
[155] The third Formulation, 2C, was prepared in accordance with Formulation 1A, as set out in Table 1, in accordance with the modalities of the invention, Formulation 2C had a density of 3 lb / gal. The progression of the test is shown in FIGS. 25-27. As can be seen in FIG. 27, after 1/8 inch of deflection, the sample did not crack (unlike comparative Formulations 2A and 2B). In addition, as can be seen in FIG. 28, Formulation 2C did not crack or break, as it was further folded. In fact, even as Formulation 2C was fully folded to form a loop, as can be seen in FIG. 29, the sample did not break or crack.
[156] Formulation 2C will be understood to convey the most desirable finishing attributes of a drywall joint compound. For example, Formulation 2C did not contract when dry. In addition, Formulation 2C remained flexible enough to resist cracking (as opposed to the conventional brittle compounds shown in Formulations 2A and 2B) but was sufficiently rigid to allow for easy sanding and smoothing of the surface. Formulation 2C can also be easily painted. EXAMPLE 3
[157] This example establishes five sample sets of formulations (2D-F, 3A-C, 4A-C, 5A-C and 6A-C) illustrating a joint compound in accordance with the modalities of the invention.
[158] It will be understood that formulations can be prepared in any suitable manner, for example, as described in Example 1. For example, the composition can be prepared on a plant scale in a horizontal cable mixer with helical blade configuration or similar to promote proper mixing dynamics as will be understood by a person ordinarily skilled in the art.
[159] It will be understood that "added water" refers to additional water not already present in any of the ingredients. Table 4
Table 5

Table 6
Table 7

Table 8

EXAMPLE 4
[160] The example below illustrates superior flexibility, crack resistance, and strength over commercially available joint compounds when used in the new joint system and tested using ASTM C474.
[161] Formulations 1A and 2E, as described above, were prepared. In addition, a conventional all-purpose joint compound (Formulation AP) and a light all-purpose joint compound (Formulation LW) were used for comparison purposes. Formulation AP was Joint Compound for All Purposes of the SHEETROCK® Brand, and Formulation LW was Light Joint Compound for All Purposes of the SHEETROCK® Brand. Each sample was prepared in triplicate.
[162] Each Formulation was prepared and tested according to ASTM C474 conducted as follows. The joint compounds were applied along a gap created in the seam of the plasterboard with a waxed spacer. A synthetic joint tape was affixed to the plaster panel joint. The samples were stacked on top of the tape and conditioned for 24 hours at 70 ° F (about 21 ° C) and 50% relative humidity. Waxed spacers were removed, and samples were mounted on test fixtures. The fixation was loaded onto the Universal Testing Machine (UTM).
[163] Each joint system was tested under a load at 0.4 inches / min. (about 1 cm / min.) at a constant rate of displacement until the sample fails. The load and displacement were recorded twice - first when a first visual crack was observed, and second when the system failed.
[164] FIGS. 30-34 show the superiority of Formulations 1A and 2E over comparative AP and LW Formulations under test conditions.
[165] FIG. 30 is a box plot graph showing the stress displacement when the first crack was observed and was measured in inches along the y-axis, and various joint compounds along the x-axis, specifically Formulations 1A and 2E, according to with modalities of the invention, and Formulations AP and LW as comparative examples. The graph illustrates that Formulations 1A and 2E were displaced about 0.12 inches (about 0.3 cm) before the first crack was observed. On the other hand, the first crack was seen in Formulation AP at 0.06 inches (about 0.15 cm) and the first crack in Formulation LW was seen at 0.08 inches (about 0.2 cm). It is noteworthy that Formulations 1A and 2E do not visibly crack due to displacement. They showed cracks only after the underlying joint tape failed and gave way. Thus, Formulations 1A and 2E demonstrated significantly higher crack resistance compared to the commercially available compounds, Formulations AP and LW.
[166] FIG. 31 is a box plot graph showing the load (lbs) when the first crack was observed and was measured in pounds (lbs) along the y-axis, and various joint compounds along the x-axis, specifically Formulations 1A and 2E, according to the modalities of the invention, and Formulations AP and LW as comparative examples. The graph illustrates that Formulations 1A and 2E were able to withstand 124 lb (about 56 kg) and 95 lb (about 43 lb), respectively, when the first crack appeared. On the other hand, the first crack in Formulation AP was seen when the load was 53 lb (about 24 kg) and the first crack in Formulation LW was seen when the load was 60 lb (about 27 kg). It is noteworthy that Formulations 1A and 2E do not visibly crack due to displacement. They showed cracks only after the underlying joint tape failed and gave way. Thus, Formulations 1A and 2E demonstrated significantly higher crack resistance and were able to withstand significantly higher loads before failure compared to the commercially available compounds, Formulations AP and LW.
[167] FIG. 32 is a box plot graph showing the shear displacement in inches when the first crack was observed, and measured in inches along the y-axis, and various joint compounds along the x-axis, specifically Formulations 1A and 2E, according to modalities of the invention, and Formulations AP and LW as comparative examples. The graph illustrates that Formulations 1A and 2E were displaced about 0.11 and 0.12 inches (about 0.3 cm), respectively, before the first crack was observed. On the other hand, the first crack was seen in Formulation AP at 0.08 inches (about 0.2 cm) and the first crack in Formulation LW was seen at 0.11 inches (about 0.3 cm). It is noteworthy that Formulations 1A and 2E do not visibly crack due to displacement. They showed cracks only after the underlying joint tape failed and gave way. Thus, there is a great variation in the data range for Formulations 1A and 2E. However, Formulations and AP and LW visibly cracked / fractured well before the joint and splice tape failed. Thus, Formulations 1A and 2E demonstrated significantly higher shear crack strength compared to the commercially available compounds, Formulations AP and LW.
[168] FIG. 33 is a box plot graph showing the peak shear displacement when the first crack was observed, measured in inches along the y-axis, and various joint compounds along the x-axis, specifically Formulations 1A and 2E, of according to modalities of the invention, and Formulations AP and LW as comparative examples. The graph illustrates that the peak shear displacement for Formulations 1A and 2E was 0.23 inches (about 0.6 cm) and 0.25 inches (about 0.6 cm), respectively, prior to observation of the first crack. On the other hand, the first crack was observed in Formulation AP after a 0.1 inch (about 0.25 cm) peak shear displacement and the first crack in Formulation LW was observed at a shear peak displacement of 0 , 13 inches (about 0.3 cm). It is noteworthy that Formulations 1A and 2E do not visibly crack due to displacement. They showed cracks only after the underlying joint tape failed and gave way. Thus, Formulations 1A and 2E demonstrated a significantly higher peak shear shift compared to the commercially available compounds, Formulations AP and LW.
[169] FIG. 34 is a box plot graph showing the shear displacement ratio (ie, the peak displacement ratio in the failure of the joint system to the displacement in the first crack) along the y-axis, and various joint compounds to the along the x-axis, specifically Formulations 1A and 2E, according to modalities of the invention, and Formulations AP and LW as comparative examples. The graph illustrates that Formulations 1A and 2E had a shear displacement ratio of about 2.3 before the first crack was observed, but Formulation AP had a shear displacement ratio of about 1.3, and Formulation LW had a shear displacement ratio of 1.2. Thus, Formulations 1A and 2E demonstrated greater elongation and stretching properties even after observing the first crack, until they reached total failure through a tear in the joint system. It is noteworthy that Formulations 1A and 2E do not visibly crack due to displacement. They showed cracks only after the underlying joint tape failed and gave way. On the other hand, Formulation AP and LW compounds are fragile materials and demonstrated peak displacement shortly after the first crack was visible.
[170] The results of this Example illustrate that when the joint system was put into tension, both Formulations 1A and 2E demonstrated superior elongation and physical displacement before failure, while Formulations AP and LW were fragile and did not give similar performance under the same test condition as the gasket system of the present invention. In addition, these commercially available joint compounds did not perform any better than conventional joint systems.
[171] When the joint system of the present invention was tested under shear forces, the differences between the joint compounds of the present invention and conventional joint compounds became even more apparent. The joint compounds in this example exhibited higher higher displacements and higher displacement ratios than the commercially available joint compounds. Thus, the joint compounds of the present invention have demonstrated a high strength and crack resistance. EXAMPLE 5
[172] This Example illustrates the flexibility and superior elastomeric properties or flexibility / degree of embrittlement when used in the new joint system and tested using ASTM C711.
[173] Each Formulation was prepared and tested according to ASTM C711 conducted as follows. Samples of Formulations 1A and 2E were prepared, and representative commercially available joint compounds, Formulation AP - Joint Compound for All Purposes of the SHEETROCK® Brand and Formulation LW - Light Joint Compound for All Purposes of the SHEETROCK® Brand, were used. for comparison purposes. Each sample was prepared in triplicate.
[174] A 1/8 inch (about 0.3 cm) thick strip of joint compound (2 "x 10") (about 5 cm x about 25 cm) was placed over a cracking film bonding material, that is, the joint compound does not adhere to the film after drying. The samples were prepared in triplicate for each environmental condition. The samples were then dried under four different test environmental conditions for 24 hours. A second set of tests was conducted after conditioning for 28 days. The samples were removed from the bond breaking film and were subjected to a bend condition around a 1 inch (about 2.5 cm) diameter cylindrical mandrel to assess the elastomeric and flexibility properties of the joint compounds. The samples were then visually rated on a 3-rating scale to determine the degree of elastomeric flexibility properties illustrated by ASTM C711.
[175] It should be noted that ASTM C711 published in 2009 illustrates with photographs the differences between a satisfactory joint compound and unsatisfactory joint compounds when assembled and bent around a mandrel according to the test. One provides a representation of a satisfactory joint compound that would receive the grade to pass due to an absence of crack or any visible flaw. Another depicts an unsatisfactory joint compound that would receive a Fail-A grade due to severe cracks. A third shows an unsatisfactory joint compound that would receive a Fail-B grade due to complete cracking and adhesion failure. Table 9 FLEXIBILITY RESULTS - ASTM C711
Table 10 FLEXIBILITY RESULTS - ASTM C711


[176] Table 9 demonstrates the results of the visual test after conditioning the samples in four different conditions of ASTM C711 for 24 hours. Specimen Formulations 1A and 2E performed significantly better than the conventional joint compounds represented by Formulations AP and LW. While Formulations 1A and 2E received a grade to pass each of the standard condition tests, Formulations AP and LW received a Fail-B grade.
[177] Table 10 shows the results of the visual test after conditioning the samples in four different conditions of ASTM C711 for 28 days. Specimen Formulations 1A and 2E performed significantly better than the conventional joint compounds represented by Formulations AP and LW. While Formulations 1A and 2E received a grade to pass each of the standard condition tests, Formulations AP and LW received a Fail-B grade.
[178] Conventional joint compounds were so fragile under these test conditions that they failed when bent with even less than 1/8 inch deflection and could not be bent around the cylindrical chuck without catastrophic failure. The performance of the joint compound under these test conditions helps to ensure the structural suitability and durability of the joint compounds. EXAMPLE 6
[179] This Example illustrates the superior properties of the joint compounds and joint system under the actual conditions that are representative of those found in service. The performance criteria based on data from these tests guarantee the structural suitability of the joint compound and joint systems during their useful life.
[180] The joint system of the present invention and the conventional joint system were tested using modified ASTM E72 as follows. The wall mount joint system of the present invention was prepared using compounds from Formulations 1A and 2E and compared with Formulations AP and LW. Samples of Formulations 1A and 2E were prepared, and representative commercially available joint compounds, Formulation AP - Joint Compound for All Purposes of the SHEETROCK® Brand and Formulation LW - Light Joint Compound for All Purposes of the SHEETROCK® Brand, were used. for comparison purposes. Formulation AP represents a conventional all-purpose joint compound. Formulation LW represents an all-purpose lightweight joint compound.
[181] Formulations 1A and 2E were used to prepare a test under the Flat Joint Treatment (square edge / edge and tapered edge joints). In this system, the joint seams were tapered using the synthetic joint reinforcement tape to affix the joint plates with an adhesive. A single layer of Formulation 1A or 2E was applied over the joint seams joined with tape. The fasteners were prepared by applying a layer of the Joint Compound Formulation 1A or 2E of the present invention on the fasteners.
[182] For comparison, conventional joint systems are generally prepared by joining all flat joint seams with tape, using paper joint reinforcement tape affixed to the joint plate with joint compound of Formulation AP or LW. Three (3) separate layers of the joint compound of Formulation AP or LW were applied over the joint joints joined with tape. The fasteners were prepared by three (3) separate layers of joint compound of Formulation AP or LW applied on the fasteners.
[183] FIG. 35A - 35C illustrate a structure mounting system by ASTM E72 modified to test the strength of the wall in civil construction.
[184] FIG. 35A illustrates a structure mounting system by ASTM E72 modified with an 8 'x 8' assembly (about 2.4 mx about 2.4 m), prepared from 2 "x 4" wooden beams ( about 5 cm x about 10 cm). The wooden beams are not shown. The assembly consists of two 48 "x 64" plates (about 1.2 mx about 1.6 m) and two 48 "x 16" plates (about 1.2 mx about 0.4 m) in a configuration staggered. Two main seams are shown with dotted lines - a horizontal joint at the level of half the height (about 4 'or about 1.2 m) and two vertical joints located at the splice of the two plates.
[185] FIG. 35B illustrates the modified ASTM E72 frame assembly system of FIG. 35A configured with 2 "x 4" wooden beams placed 16 inches (about 0.4 m) apart. It also illustrates the two seams - a horizontal joint at the level of half the height (about 4 'or about 1.2 m) and two vertical seams located at the joint of the two boards supported on the wooden beams.
[186] FIG. 35C illustrates the modified ASTM E72 frame assembly system of FIG. 35B, where the lower part was rigidly fixed to the structure, and a force was applied in the upper left corner by a hydraulic ram programmed to execute a sinusoidal waveform with varying amplitudes.
[187] During this test, the plane of the plate in these frame assembly systems was allowed to move only in the same plane as the face of the wall. The computer-controlled hydraulic ram was programmed to perform a 0.025 "(about 0.06 cm) amplitude sine waveform with a frequency of 0.5 Hz (2 seconds per cycle) for a cycle count of 500 and hammer the top left corner of the assembly. After completing this cycle, the span has been increased to 0.050 "(about 0.12 cm) for a cycle count of 500 cycles. After the completion of the second cycle, again, the amplitude was increased to 0.075 "(about 0.18 cm) for a cycle count of 500 cycles. This was repeated until the amplitude reached 0.400" (about 1 cm). During this rigorous test, the assembly was monitored continuously, and when a failure was observed, the cycle count was noted along with the location of the failure.
[188] The results show a significant advantage of the elastic membrane effect of Formulations 1A and 2E. Even in areas where fasteners failed to mount the wall, the joint compounds had not been broken or punctured. While in the conventional comparative system prepared by conventional joint compounds, for example, AP and LW Formulations, a brittle fracturing effect was observed, including loss of bonding on the fasteners. EXAMPLE 7
[189] This Example illustrates the superior drying properties of the joint system of the present invention.
[190] As discussed in the specification, existing joint compounds require that three separate layers be applied to fasteners, as well as several layers applied to flat seams between plates on the same plane. Each layer must dry separately before applying a new layer. While the existing layer does not need to dry completely, it turns out that about 75% of the water content must evaporate from the compost before the layer becomes firm enough to receive a second layer. This creates a significant period of downtime, during which other construction companies cannot normally work within the construction while wall finishing is taking place.
[191] On the other hand, the joint compounds of the present invention only require a single layer over the splice to provide a uniform aesthetic appearance. In the event that a second layer is required to compensate for imperfect finish and the like, the joint compounds of the present invention become firm enough to receive the second layer when about 60% of the water evaporates from the compound.
[192] Samples of Formulations 1A, 2E, 3A and 4B were prepared. In addition, a conventional all-purpose joint compound (Formulation AP), as well as an all-purpose lightweight joint compound (Formulation LW) were used for comparison purposes. Formulation AP was Joint Compound for All Purposes of the SHEETROCK® Brand, and Formulation LW was Light Joint Compound for All Purposes of the SHEETROCK® Brand.
[193] FIGS. 36A to 36C show the drying profile of the joint compounds of the present invention compared to conventional joint compounds for a thick layer, i.e., about 3/16 inch (about 0.5 cm), in which the percentage of evaporated water (y-axis) was plotted against the increasing drying times represented along (x-axis). FIG. 36A shows the drying profiles in a moderate environment, for example, 75 ° F and 50% relative humidity. FIG. 36B shows the drying profiles in a hot and dry environment, for example, 95 ° F and 10% relative humidity. FIG. 36C shows the drying profiles in a cold and humid environment, for example, 40 ° F and 80% relative humidity.
[194] A thick layer (3/16 inch; about 0.5 cm) is representative of several applications, for example, 1- or 2- layer on the corner reinforcement chip; 1- or 2- layer on panel / wall edges; 1- or 2- layer over square edge joints; and 2- fill layer over tapered edge joints.
[195] As seen in FIG. 36A, 3/16 inch (about 0.5 cm) layers of Formulations 1A, 2E, 3A and 4B illustrate similar drying profiles in a moderate environment. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 1.5 to 4.5 hours. On the other hand, the thick layer of Formulation LW was ready to receive a second layer in about 13 to 15 hours, while the thick layer of Formulation AP was not ready even after 24 hours.
[196] As seen in FIG. 36B, 3/16 inch (about 0.5 cm) layers of Formulations 1A, 2E, 3A and 4B illustrate similar drying profiles in a hot-dry environment. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 1 to 3 hours. On the other hand, the thick layers of Formulations LW and AP were ready to receive a second layer in about 4 to 5.5 hours.
[197] As can be seen in FIG. 36C, 3/16 inch (about 0.5 cm) layers of Formulations 2E and 4B demonstrated the fastest drying times in a cold-wet environment followed by Formulations 3A and 1A. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 5 to 12.5 hours. On the other hand, the thick layers of Formulations LW and AP were not ready to receive a second layer even after 24 hours.
[198] FIGS. 37A to 37C show the drying profiles of the joint compounds of the present invention compared to conventional joint compounds for a thin layer, i.e., about 1/16 inch (about 0.2 cm), in which the percentage of evaporated water (y-axis) was plotted against the increasing drying times represented along (x-axis). FIG. 37A shows the drying profiles in a moderate environment, for example, 75 ° F and 50% relative humidity. FIG. 37B shows the drying profiles in a hot and dry environment, for example, 95 ° F and 10% relative humidity. FIG. 37C shows the drying profiles in a cold and humid environment, for example, 40 ° F and 80% relative humidity.
[199] A thin layer (1/16 inch; about 0.2 cm) is representative of several applications, for example, 1- or 2- layer on the inner corner finish; 1-, 2- or 3- finishing layer on flat joints; 3- layer over the square edge margin joints; and 1st, 2- or 3- layer on the fasteners.
[200] As seen in FIG. 37A, 1/16 inch (about 0.2 cm) layers of Formulations 1A, 2E, 3A and 4B illustrate similar drying profiles in a moderate environment. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 0.5 to less than 2 hours. On the other hand, the thin layers of Formulations LW and AP were ready to receive a second layer in about 3.5 to 10 hours.
[201] As seen in FIG. 37B, 1/16 inch (about 0.2 cm) layers of Formulations 1A, 2E, 3A and 4B illustrate similar drying profiles in a hot-dry environment. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 1 hour. On the other hand, the thin layers of Formulations LW and AP were ready to receive a second layer in about 1.5 to more than 2 hours.
[202] As seen in FIG. 37C, 1/16 inch (about 0.2 cm) layers of Formulations 1A, 2E, 3A and 4B illustrate profiles of similar drying times in a cold-humid environment. If a second layer is needed, the first layers of Formulations 1A, 2E, 3A and 4B were ready in 0.5 to less than 3 hours. On the other hand, the thin layers of Formulations LW and AP were ready to receive a second layer only after 7 to more than 10 hours.
[203] Thus, this Example shows that the joint compounds of the present invention had a faster drying profile in each of the different test environments than the conventional joint compound.
[204] The use of the terms "one" and "one" and "the (s)" and "at least one (a)" and similar referents in the context of the description of the invention (especially in the context of the following claims) it must be interpreted to encompass both the singular and the plural, unless otherwise stated in this document or in the event of a clear contradiction in context. The use of the term "at least one (a)" followed by a list of one or more items (for example, "at least one of A and B") should be interpreted in the sense of an item selected from the items listed (A or B) or any combination of two or more of the items listed (A and B), unless otherwise stated in this document or in the event of a clear contradiction in context. The terms "comprising", "having" "including" and "containing" are to be interpreted as open terms (ie, meaning "including, but not limited to") unless otherwise stated. Recitation of the ranges of values in this document are only intended to serve as an abbreviated method of referring individually to each separate value that falls within the range, unless otherwise specified in this document, and each separate value is incorporated into the specification as if it were individually recited in this document. All methods described in this document may be performed in any appropriate order, unless otherwise stated in this document, or in the event of a clear contradiction in context. The use of any and all examples, or exemplary language (for example, "such as") provided in this document, is intended only to better illuminate the invention and does not represent a limitation on the scope of the invention, unless otherwise stated . No language in the specification should be interpreted as indicating any element not claimed as essential to the practice of the invention.
[205] Preferred embodiments of this invention are described in this document, including the best way known to the inventors for carrying out the invention. Variations in these preferred modalities may become apparent to those ordinarily versed in the technique by reading the description above. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced in ways other than just as specifically described in this document. Accordingly, this invention includes all modifications and equivalents of the matter recited in the appended claims here as permitted by applicable law. In addition, any combination of the elements described above in all possible variations of them is covered by the invention, unless otherwise stated in this document or in the event of a clear contradiction in context.

权利要求:
Claims (12)
[0001]
1. Drying-type joint compound composition, to fill seams in a set of walls, the drying-type joint compound composition characterized by the fact that it comprises: (a) latex emulsion binder in an amount of 3% to 90% by weight of the wet composition; and (b) a plurality of hollow spheres having an average isostatic crush resistance of at least about 100 psi (689.48 kpa), as measured according to ASTM D3102-78, wherein the spheres are present in an amount of 5% to 25% by weight of the wet composition; (c) non-ionic surfactant in an amount of 0.001% to 5% by weight of the wet composition; and (d) wetting in an amount of 0.001% to 3% by weight of the wet composition; wherein the composition further comprises at least one of the following compounds: calcium carbonate in an amount of 1% to 40% by weight of the wet composition, a defoamer in an amount of 0.05% to 5%, by weight of the wet composition ; a rheological modifier in an amount of 0.1% to 5%, by weight of the wet composition; and a biocide in an amount of 0.1% to 1.5%, by weight of the wet composition;
[0002]
2. Joint compound composition according to claim 1, characterized by the fact that the composition has a density of 239.652 kg / m3 (2 lb / gal), to 958.608 kg / m3 (8 lb / gal) and in that the composition exhibits a contraction of 2% or less, as measured by ASTM C474-05.
[0003]
3. Joint compound composition according to claim 1, characterized by the fact that the binder has a glass transition temperature (Tg) from 0 ° C (32 ° F) to 21 ° C (70 ° F).
[0004]
4. Joint compound composition according to claim 1, characterized by the fact that the binder has a minimum film-forming temperature (MMFT) of 0 ° C (32 ° F) to 32 ° C (90 ° F) ).
[0005]
Gasket compound composition according to claim 1, characterized in that the spheres have an isostatic crush resistance of at least 250 psi (1723.69 kpa).
[0006]
6. Joint compound composition according to claim 1, characterized in that the spheres have a density of 41.52 kg / m3 (0.0015 lb / in3) to 1107.20 kg / m3 (0, 04 lb / in3).
[0007]
7. Joint compound composition according to claim 1, characterized in that the spheres comprise limestone borosilicate, polystyrene, ceramics, recycled glass, expanded glass and lightweight, thermoplastic, thermoset polyolefin beads or any other combinations.
[0008]
8. Wall mounting, characterized by the fact that it comprises: (a) two adjacent plates, joined by a splice; (b) only one layer of the joint compound composition, as defined in claim 1, in the splice to provide a uniform aesthetic appearance; and (c) flat, non-expandable, dimensionally stable joint tape incorporated into the splice.
[0009]
9. Wall mounting according to claim 8, characterized by the fact that at least one plate has a tapered edge adjacent to the seam, the taper having a maximum depth of 0.318 cm (0.125 inches) or less.
[0010]
10. Wall mounting according to claim 8, characterized in that the plates comprise opposite front and rear surfaces, in which the faces of two adjacent plates are arranged in relation to each other to define an internal corner at an angle corner between the faces of the plate from 30 ° to 180 °, and additionally comprises a reinforcement chip arranged on the seam, wherein the chip comprises (i) a coating material comprising paper with a dimensional stability less than 0.4 % longitudinal expansion and less than 2.5% transverse expansion after 30 minutes immersion in water, as measured according to ASTM C474-05, Section 12 and (11) a reinforcement liner comprising paper, plastic, natural fiber or synthetic, carbon fiber, polyester, polycarbonate, fiberglass, natural or synthetic non-woven materials, natural or synthetic woven materials, twisted polyolefin, or metal, where the lining has a thickness of 0.0305 cm (0.012 pole 0.159 cm (0.0625 inches).
[0011]
11. Wall mounting according to claim 8, characterized in that it additionally comprises at least one molding and adhesive member, wherein the adhesive, at least partially, affixes at least one plate to the molding member.
[0012]
12. Method for treating a drywall assembly of two adjacent boards joined by a splice, the method characterized by the fact that it comprises: (a) applying joint tape and a layer of the joint compound composition as defined in claim 1, to amendment; and (b) drying the composition.

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法律状态:
2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |

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2019-11-19| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-06-09| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2020-12-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-01-19| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 25/09/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201261705551P| true| 2012-09-25|2012-09-25|

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US61/705,551|2012-09-25|

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US13/842,342|2013-03-15|

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US13/842,342|US8931230B2|2012-09-25|2013-03-15|Joint compound, wall assembly, and methods and products related thereto|

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US14/034,290|US9169426B2|2012-09-25|2013-09-23|Joint compound, wall assembly, and methods and products related thereto|

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US14/034,290|2013-09-23|

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PCT/US2013/061521|WO2014052349A1|2012-09-25|2013-09-25|Joint compound, wall assembly, and methods and products related thereto|

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