DESC:FIELD
The present disclosure relates to a composition of joint compound and a process for its preparation.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Surface pretreatment: The term “surface pretreatment” refers to a process of cleaning and preparing the surface for further processing.
Elastomeric: The term “elastomeric” refers to the rubber like properties of a material. The elastomeric materials have the tendency to regain their original shape upon removal of load.
Joint Compound: The term “joint compound” refers to a matter/material used in construction that is used to seal joints that exist between drywall sheets.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
In the construction industry, different types of boards such as cement boards, and gypsum boards are often used for improving the aesthetics of wall surfaces. The boards are cut into the desired size and fastened to the stud/frames fixed to the walls by using fasteners like screws and nails. Suitable materials should be used to fill the joints formed between two boards to address both aesthetic and protective considerations.
Conventionally, joint compounds are used to fill the joints formed between two such boards to address both aesthetic and protective requirements. After the application of the joint compound, the joints are covered using reinforcement tapes such as fiber tape, paper tape, and the like to hold the jointing compound in the joint till it gets dried.
Further, the joints between boards are also filled by using formulations such as water based emulsions, solvent based emulsions, epoxy based systems, and the like. However, these conventional formulations are associated with drawbacks such as multiple coats are required to apply on the joints of the boards and the fasteners so that the entire wall surface should appear smooth, uniform, and flat, thereby making the process costly.
The conventional methods are not fully satisfactory, as it affects the aesthetic of the surface. Further, an advanced level of skill is required to apply the reinforcement tape effectively and removal of the same. Furthermore, the known composition of joint compounds cannot withstand vibration, resulting in cracking of the joint.
Therefore, there is felt a need to provide a composition of joint compound and a process for its preparation that can mitigate the drawbacks mentioned hereinabove or at least provides an alternative solution.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide a composition of joint compound.
Yet another object of the present disclosure is to provide a composition of joint compound that can be used for joining boards such as cement boards, calcium silicate boards, and gypsum boards.
Still another object of the present disclosure is to provide a composition of joint compound that can withstand vibrations without developing cracks.
Yet another object of the present disclosure is to provide a composition of joint compound that does not require multiple coats.
Still another object of the present disclosure is to provide a simple and economic process for the preparation of a composition of joint compound.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a composition of joint compound, a process for its preparation and a method of applying the composition of joint compound.
In one aspect, the present disclosure relates to a composition of joint compound. The composition of joint compound comprises:
i) a predetermined amount of at least one binder;
ii) a predetermined amount of an extender;
iii) a predetermined amount of at least one thickener;
iv) a predetermined amount of at least one reinforcing agent;
v) a predetermined amount of at least one additive;
vi) q.s water;
vii) optionally a predetermined amount of at least one adhesion promoter; and
viii) optionally a predetermined amount of at least one corrosion inhibitor.
In an embodiment of the present disclosure, the predetermined amount of binder is in the range of 5 mass% to 30 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of extender is in the range of 50 mass% to 70 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of thickener is in the range of 0.1 mass% to 5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of the reinforcing agent is in the range of 0.2 mass% to 2 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of additive is in the range of 1 mass% to 10 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of adhesion promoter is in the range of 0 mass % to 0.5 mass % based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of the corrosion inhibitor is in the range of 0 mass% to 2 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, a ratio of the binder to the extender is in the range of 1:2 to 1:10.
In an embodiment of the present disclosure, the binder is selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion.
In an embodiment of the present disclosure, the extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder.
In an embodiment of the present disclosure, the thickener is selected from the group consisting of clay based thickeners, acrylic thickeners, and hydrophobically modified ethylene oxide urethane (HEUR) thickener.
In an embodiment of the present disclosure, the additive is selected from the group consisting of a dispersing agent, a wetting agent, a pH stabilizer, a defoaming agent, an anti-freezing agent, a preservative, and a coalescing agent.
In an embodiment of the present disclosure, the adhesion promoter is selected from the group consisting of epoxy functional silane, beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (silquest 187), and beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane(LX-A-11933).
In an embodiment of the present disclosure, the corrosion inhibitor is sodium hexametaphosphate (SHMP).
In an embodiment of the present disclosure, wherein the composition is characterized by having a viscosity in the range of 350 KU to 370 KU.
In a second aspect, the present disclosure provides a process for preparation of the composition of joint compound. The process comprises the following steps:
i) mixing predetermined amounts of water, a predetermined amount of preservatives, and a predetermined amount of clay based thickeners in a ribbon blender under stirring at temperature in the range of 25 °C to 40 °C for a first predetermined time period to obtain a first mixture;
ii) adding a predetermined amounts of pH stabilizer, dispersing agent, wetting agent, defoaming agent, and anti-freezing agent to the first mixture under stirring for a second predetermined time period to obtain a second mixture;
iii) adding a predetermined amount of an extender to the second mixture under stirring at a third predetermined speed for a third predetermined time period to obtain a third mixture;
iv) adding a predetermined amount of a binder to the third mixture under stirring at a fourth predetermined speed for a fourth predetermined time period to obtain a fourth mixture; and
v) adding predetermined amounts of coalescing agent, acrylic thickener, reinforcing agent, optionally corrosion inhibitor, HEUR and adhesion promotor are added to the fourth mixture under stirring at a fifth predetermined speed for a fifth predetermined time period to obtain the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 5 mass % to 25 mass with respect to the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of preservative is in the range of 0.1 mass % to 1 mass% with respect to the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the preservative is selected from the group consisting of aqueous formulation of isothiazolinones, aqueous formulation of glycol, aqueous formulation of formaldehyde (Preventol D 6), (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one, and 2-Methyl-2,3-dihydroisothiazol-3-one (3:1) (Nipacide CFX 3).
In an embodiment of the present disclosure, the predetermined amount of clay based thickeners is in the range of 0.1 mass % to 2 mass% with respect to the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the clay based thickener is at least one selected from the group consisting of organically modified bentonite based rheological additive for water based system (bentec P-LC). and bentonite.
In an embodiment of the present disclosure, the stirring is in the range of 20 rpm to 50 rpm.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 10 minutes to 20 minutes.
In an embodiment of the present disclosure, the predetermined amount of the pH stabilizer is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the pH stabilizer is at least one selected from the group consisting of monoethanolamine (Falamine Plus) and 2-aminoethanol (Genamin NT 18).
In an embodiment of the present disclosure, the predetermined amount of the dispersing agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the dispersing agent is at least one selected from the group consisting of sodium salt of carboxylic acid (Indofil 850) and polyacrylate sodium salt (Ecodis 30:30).
In an embodiment of the present disclosure, the predetermined amount of the wetting agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the wetting agent is at least one selected from the group alkyl polyethylene glycol ether with 40 mole ethylene oxide (Emulsogen LCN 407) and ethylene oxide condensate of alkyl phenol (Alphox 200).
In an embodiment of the present disclosure, the predetermined amount of the defoaming agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the defoaming agent is at least one selected from the group consisting of hydrocarbon oil based antifoaming agent (Advantage AM 1512A) and hydrocarbon oil based antifoaming agent (Saurafoam 90).
In an embodiment of the present disclosure, the predetermined amount of the anti-freezing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the anti-freezing agent is at least one selected from the group consisting of diethylene glycol, monoethylene glycol and polypropylene glycol.
In an embodiment of the present disclosure, the second predetermined speed is in the range of 20 rpm to 50 rpm.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 5 minutes to 10 minutes.
In an embodiment of the present disclosure, the extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder.
In an embodiment of the present disclosure, the predetermined amount of the predetermined amount of extender is in the range of 50 mass% to 70 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the third predetermined speed is in the range of 20 rpm to 50 rpm.
In an embodiment of the present disclosure, the third predetermined time period is in the range of 15 minutes to 20 minutes.
In an embodiment of the present disclosure, the predetermined amount of the binder is in the range of 5 mass% to 30 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the binder is at least one selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion.
In an embodiment of the present disclosure, the fourth predetermined time period is in the range of 15 minutes to 20 minutes.
In an embodiment of the present disclosure, the predetermined amount of the coalescing agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (texanol) and 2,2,4-trimethyl-1,3-pentanediol diisobutyrate.
In an embodiment of the present disclosure, the acrylic thickener is at least one selected from the group consisting of aqueous alkylphenol ethoxylates (APEO) and formaldehyde free acidic cross-linked acrylic thickener (visicryl 828) and anionic cross-linked acrylic copolymer emulsion (bondex T 60).
In an embodiment of the present disclosure, the predetermined amount of the acrylic thickener is in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the fifth predetermined time period is in the range of 5 minutes to 20 minutes.
DETAILED DESCRIPTION
The present disclosure relates to a composition of joint compound and a process for its preparation.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
In the construction industry, different types of boards such as cement boards, and gypsum boards are often used for improving the aesthetics of wall surfaces. The boards are cut into the desired size and fastened to the stud/frames fixed to the walls by using fasteners like screws and nails. Suitable materials should be used to fill the joints formed between two boards to address both aesthetic and protective considerations.
Conventionally, joint compounds are used to fill the joints formed between two such boards to address both aesthetic and protective requirements. After the application of the joint compound, the joints are covered using reinforcement tapes such as fiber tape, paper tape, and the like to hold the jointing compound in the joint till it gets dried.
Further, the joints between boards are also filled by using formulations such as water based emulsions, solvent based emulsions, epoxy based systems, and the like. However, these conventional formulations are associated with drawbacks such as multiple coats are required to apply on the joints of the boards and the fasteners so that the entire wall surface should appear smooth, uniform, and flat, thereby making the process costly.
The conventional methods are not fully satisfactory, as it affects the aesthetic of the surface. Further, an advanced level of skill is required to apply the reinforcement tape effectively and removal of the same. Furthermore, the known composition of joint compounds cannot withstand vibration, resulting in cracking of the joint.
The present disclosure provides a composition of joint compound, a process for the preparation of a composition of joint compound, and a method of applying the composition of joint compound.
In an aspect a composition of joint compound comprises a predetermined amount of at least one binder; a predetermined amount of a extender; a predetermined amount of at least one thickener; a predetermined amount of at least one reinforcing agent; a predetermined amount of at least one additive; q.s water; optionally a predetermined amount of at least one adhesion promoter; and optionally a predetermined amount of at least one corrosion inhibitor.
In an embodiment of the present disclosure, the predetermined amount of binder is in the range of 5 mass% to 30 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of binder is 13 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of extender is in the range of 50 mass% to 70 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of extender is 65 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of thickener is in the range of 0.1 mass% to 5 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of thickener is 1.8 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of the reinforcing agent is in the range of 0.2 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of the reinforcing agent is 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of additive is in the range of 1 mass% to 10 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of additive is 3.78 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 5 mass % to 25 mass % based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of water is 16 mass % based on the total mass of the composition of joint compound. In another exemplary embodiment of the present disclosure, the predetermined amount of water is 17 mass % based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of adhesion promoter is in the range of 0 mass % to 0.5 mass % based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of adhesion promoter is 0.05 mass % based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the predetermined amount of corrosion inhibitor is in the range of 0 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of corrosion inhibitor is 0.6 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, a ratio of the binder to the extender is in the range of 1:2 to 1:10. In an exemplary embodiment of the present disclosure, a ratio of the binder to the extender is of 1:5.
In an embodiment of the present disclosure, the binder is selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion. In an exemplary embodiment of the present disclosure, the binder is a mixture of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion.
In an embodiment of the present disclosure, the extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder. In an exemplary embodiment of the present disclosure, the extender is dolomite powder.
In an embodiment of the present disclosure, the thickener is selected from the group consisting of clay based thickeners, acrylic thickeners, and optionally hydrophobically modified ethylene oxide urethane (HEUR) thickener. In an exemplary embodiment of the present disclosure, the thickener is a mixture of clay based thickeners, acrylic thickeners, and hydrophobically modified ethylene oxide urethane (HEUR) thickener.
In an embodiment of the present disclosure, the additive is selected from the group consisting of a dispersing agent, a wetting agent, a pH stabilizer, a defoaming agent, an anti-freezing agent, a preservative, and a coalescing agent. In an exemplary embodiment of the present disclosure, the additive is a mixture of dispersing agent, a wetting agent, a pH stabilizer, a defoaming agent, an anti-freezing agent, a preservative, and a coalescing agent.
In an embodiment of the present disclosure, adhesion promoter is selected from the group consisting of epoxy functional silane, beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (silquest 187), and beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (LX-A-11933). In an exemplary embodiment of the present disclosure, the adhesion promoter is beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane(silquest 187).
In an embodiment of the present disclosure, the corrosion inhibitor is sodium hexametaphosphate (SHMP). In an exemplary embodiment of the present disclosure, the corrosion inhibitor is sodium hexametaphosphate (SHMP).
In an embodiment of the present disclosure, the copolymer emulsion of vinyl acetate ethylene (VAE) is present in an amount in the range of 3 mass% to 15 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the copolymer emulsion of vinyl acetate ethylene (VAE) is present in an amount of 6 mass based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the copolymer emulsion of styrene acrylic is present in an amount in the range of 1 mass% to 7 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the copolymer emulsion of styrene acrylic is present in an amount of 3 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the copolymer acrylic emulsion is present in an amount in the range of 1 mass% to 10 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the copolymer acrylic emulsion is present in an amount of 4 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the clay based thickener is present in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the clay based thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the acrylic thickener is present in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the acrylic thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is present in an amount in the range of 0 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the dispersing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the dispersing agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the wetting agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the wetting agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the preservative is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the preservative is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the pH stabilizer is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the pH stabilizer is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the defoaming agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the defoaming agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the anti-freezing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the anti-freezing agent is present in an amount of 0.6 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the coalescing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the coalescing agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the clay based thickener is at least one selected from the group consisting of organically modified bentonite based rheological additive for water based system (bentec P-LC). In an exemplary embodiment of the present disclosure, the clay based thickener is organically modified bentonite based rheological additive for water based system (bentec P-LC).
In an embodiment of the present disclosure, the acrylic thickener is selected from the group consisting of aqueous alkylphenol ethoxylates (APEO) and formaldehyde free acidic cross-linked acrylic thickener (visicryl 828) and anionic cross-linked acrylic copolymer emulsion (bondex T 60). In an exemplary embodiment of the present disclosure, the acrylic thickener is aqueous alkylphenol ethoxylates.
In an embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is at least one selected from the group consisting of non-ionic urethane associative thickener, and solvent-free and APEO-free HEUR thickener. In an exemplary embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is a non-ionic urethane associative thickener.
In an embodiment of the present disclosure, the reinforcing agent is selected from polypropylene fiber and acrylic fiber. In an exemplary embodiment of the present disclosure, the reinforcing agent is polypropylene fiber.
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of s sodium salt of carboxylic acid (Indofil 850) and polyacrylate sodium salt (Ecodis 30:30). In an exemplary embodiment of the present disclosure, the dispersing agent is sodium salt of carboxylic acid.
In an embodiment of the present disclosure, the wetting agent is selected from the group alkyl polyethylene glycol ether with 40 mole ethylene oxide (Emulsogen LCN 407) and ethylene oxide condensate of alkyl phenol (Alphox 200). In an exemplary embodiment of the present disclosure, the wetting agent is alkyl polyethylene glycol ether with 40 mole ethylene oxide.
In an embodiment of the present disclosure, the preservative is selected from the group consisting of an aqueous formulation of isothiazolinones and aqueous formulation of glycol, aqueous formulation of formaldehyde (Preventol D 6), (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one, and 2-Methyl-2,3-dihydroisothiazol-3-one (3:1) (Nipacide CFX 3). In an exemplary embodiment of the present disclosure, the preservative is a mixture of an aqueous formulation of isothiazolinones and glycols and an aqueous formulation of isothiazolinones and formaldehyde. In another exemplary embodiment of the present disclosure, the preservative is a mixture of (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one and 2-Methyl-2,3dihydroisothiazol-3-one (3:1).
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of monoethanolamine (Falamine Plus) and 2-aminoethanol (Genamin NT 18). In an exemplary embodiment of the present disclosure, the pH stabilizer is monoethanolamine.
In an embodiment of the present disclosure, the defoaming agent is selected from the group consisting of hydrocarbon oil based antifoaming agent (Advantage AM 1512A) and hydrocarbon oil based antifoaming agent (Saurafoam 90). In an exemplary embodiment of the present disclosure, the defoaming agent is hydrocarbon oil based antifoaming agent.
In an embodiment of the present disclosure, the anti-freezing agent is selected from the group consisting of diethylene glycol, monoethylene glycol and polypropylene glycol. In an exemplary embodiment of the present disclosure, the anti-freezing agent is diethylene glycol.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (texanol) and 2,2,4-trimethyl-1,3-pentanediol diisobutyrate. In an exemplary embodiment of the present disclosure, the coalescing agent is isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (texanol).
In an embodiment of the present disclosure, wherein the composition is characterized by having a viscosity in the range of 350 KU to 370 KU. In an exemplary embodiment of the present disclosure, the composition is characterized by having a viscosity of 360 KU.
The composition of joint compound of the present disclosure is used for joining boards such as cement board, calcium silicate board, gypsum board, and the like. Further, the composition of joint compound of the present disclosure is used for finishing the surfaces. Furthermore, the composition of joint compound of the present disclosure is used for filling gaps in the materials such as cement board, calcium silicate board, gypsum board, and the like.
The composition of joint compound of the present disclosure is easy to use. It can be used without reinforcements such as fiber tape, paper tape, and the like. Moreover, one to two coats of composition of joint compound are sufficient to fill the gap or to provide the surface finish. Thus, the composition of joint compound of the present disclosure is economic. Further, the coat obtained by applying the composition of joint compound of the present disclosure can withstand vibrations without developing cracks.
In a second aspect, the present disclosure provides a process for preparation of the composition of joint compound. The process comprises the following steps:
i) mixing predetermined amounts of water, a predetermined amount of preservatives, and a predetermined amount of clay based thickeners in a ribbon blender under stirring at temperature in the range of 25 °C to 40 °C for a first predetermined time period to obtain a first mixture;
ii) adding a predetermined amounts of pH stabilizer, dispersing agent, wetting agent, defoaming agent, and anti-freezing agent to the first mixture under stirring for a second predetermined time period to obtain a second mixture;
iii) adding a predetermined amount of extender to the second mixture under stirring for a third predetermined time period to obtain a third mixture;
iv) adding a predetermined amount of a binder to the third mixture under stirring at a fourth predetermined speed for a fourth predetermined time period to obtain a fourth mixture; and
v) adding predetermined amounts of coalescing agent, and acrylic thickener, reinforcing agent, optionally corrosion inhibitor, HEUR, and adhesion promotor in the fourth mixture under stirring at a fifth predetermined speed for a fifth predetermined time period to obtain the composition of joint compound.
The process is described in detail.
In a first step, predetermined amount of water, a predetermined amount of preservatives, and a predetermined amount of clay based thickeners is mixed in a ribbon blender under stirring at temperature in the range of 25 °C to 40 °C for a first predetermined time period to obtain a first mixture.
In an embodiment of the present disclosure, the first mixture is in the form of a gelly.
In an embodiment of the present disclosure, the predetermined amount of water is in the range of 5 mass % to 25 mass % based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of water is 16 mass % based on the total mass of the composition of joint compound. In another exemplary embodiment of the present disclosure, the predetermined amount of water is 17 mass % based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the preservative is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the preservative is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the preservative is selected from the group consisting of an aqueous formulation of isothiazolinones and glycols, an aqueous formulation of isothiazolinones and formaldehyde, (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one and 2-Methyl-2,3-dihydroisothiazol-3-one (3:1). In an exemplary embodiment of the present disclosure, the preservative is a mixture of an aqueous formulation of isothiazolinones and glycols and an aqueous formulation of isothiazolinones and formaldehyde. In another exemplary embodiment of the present disclosure, the preservative is a mixture of (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one and 2-Methyl-2,3-dihydroisothiazol-3-one (3:1).
In an embodiment of the present disclosure, the clay based thickener is present in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the clay based thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the clay based thickener is selected from the group consisting of organically modified bentonite based rheological additive for water based system (bentec P-LC), and bentonite. In an exemplary embodiment of the present disclosure, the clay based thickener is organically modified bentonite based rheological additive for water based system (bentec P-LC).
In an embodiment of the present disclosure, the first predetermined time period is in the range of 10 minutes to 20 minutes. In an exemplary embodiment of the present disclosure, the first predetermined time period is 15 minutes.
In a second step, predetermined amounts of pH stabilizer, dispersing agent, wetting agent, defoaming agent, and anti-freezing agent are added to the first mixture under stirring for a second predetermined time period to obtain a second mixture.
In an embodiment of the present disclosure, the pH stabilizer is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the pH stabilizer is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the pH stabilizer is selected from the group consisting of monoethanolamine (Falamine Plus) and 2-aminoethanol (Genamin NT 18). In an exemplary embodiment of the present disclosure, the pH stabilizer is monoethanolamine.
In an embodiment of the present disclosure, the dispersing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the dispersing agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the dispersing agent is selected from the group consisting of sodium salt of carboxylic acid (Indofil 850) and polyacrylate sodium salt (Ecodis 30:30). In an exemplary embodiment of the present disclosure, the dispersing agent is sodium salt of carboxylic acid.
In an embodiment of the present disclosure, the wetting agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the wetting agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the wetting agent is selected from the alkyl polyethylene glycol ether with 40 mole ethylene oxide (Emulsogen LCN 407) and ethylene oxide condensate of alkyl phenol (Alphox 200). In an exemplary embodiment of the present disclosure, the wetting agent is alkyl polyethylene glycol ether with 40 mole ethylene oxide.
In an embodiment of the present disclosure, the defoaming agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the defoaming agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the defoaming agent is selected from the group consisting of hydrocarbon oil based antifoaming agent (Advantage AM 1512A) and hydrocarbon oil based antifoaming agent (Saurafoam 90). In an exemplary embodiment of the present disclosure, the defoaming agent is hydrocarbon oil based antifoaming agent.
In an embodiment of the present disclosure, the anti-freezing agent is selected from the group consisting of diethylene glycol, monoethylene glycol and polypropylene glycol. In an exemplary embodiment of the present disclosure, the anti-freezing agent is diethylene glycol.
In an embodiment of the present disclosure, the anti-freezing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the anti-freezing agent is present in an amount of 0.6 mass% based on the total mass of the composition of joint compound. In another exemplary embodiment of the present disclosure, anti-freezing agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 5 minutes to 10 minutes. In an exemplary embodiment of the present disclosure, the second predetermined time period is of 7 minutes.
In a third step, a predetermined amount of extender is added to the second mixture under stirring at a third predetermined speed for a third predetermined time period to obtain a third mixture.
In an embodiment of the present disclosure, the predetermined amount of extender is in the range of 50 mass% to 70 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of extender is 65 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder. In an exemplary embodiment of the present disclosure, the extender is dolomite powder.
In an embodiment of the present disclosure, the third predetermined time period is in the range of 15 minutes to 20 minutes. In an exemplary embodiment of the present disclosure, the third predetermined time period is 17 minutes.
In a fourth step, a predetermined amount of a binder is added to the third mixture under stirring at a fourth predetermined speed for a fourth predetermined time period to obtain a fourth mixture.
In an embodiment of the present disclosure, the predetermined amount of binder is in the range of 5 mass% to 30 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of binder is 13 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the binder is selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion. In an exemplary embodiment of the present disclosure, the binder is a mixture of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion.
In an embodiment of the present disclosure, the copolymer emulsion of vinyl acetate ethylene (VAE) is present in an amount in the range of 3 mass% to 15 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the copolymer emulsion of vinyl acetate ethylene (VAE) is present in an amount of 6 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the copolymer emulsion styrene Acrylic is present in an amount in the range of 1 mass% to 5 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the copolymer emulsion styrene acrylic is present in an amount of 3 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the co polymer emulsion acrylic is present in an amount in the range of 2 mass% to 8 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the Co Polymer Emulsion Acrylicis present in an amount of 4 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the fourth predetermined time period is in the range of 15 minutes to 20 minutes. In an exemplary embodiment of the present disclosure, the fourth predetermined time period is 16 minutes.
In a final step, predetermined amounts of coalescing agent, acrylic thickener, optionally corrosion inhibitor, HEUR thickener and adhesion promotor is added to the fourth mixture under stirring at a fifth predetermined speed for a fifth predetermined time period to obtain the composition of joint compound.
In an embodiment of the present disclosure, the coalescing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the coalescing agent is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the coalescing agent is selected from the group consisting of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (texanol) and 2,2,4-trimethyl-1,3-pentanediol diisobutyrate. In an exemplary embodiment of the present disclosure, the coalescing agent is isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester.
In an embodiment of the present disclosure, the acrylic thickener is present in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the acrylic thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the acrylic thickener is selected from the group consisting of aqueous alkylphenol ethoxylates, formaldehyde free acidic cross-linked acrylic thickener and anionic cross-linked acrylic copolymer emulsion. In an exemplary embodiment of the present disclosure, the acrylic thickener is aqueous alkylphenol ethoxylates.
In an embodiment of the present disclosure, the predetermined amount of corrosion inhibitor is in the range of 0 mass% to 2 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of corrosion inhibitor is 0.6 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the corrosion inhibitor is sodium hexametaphosphate (SHMP). In an exemplary embodiment of the present disclosure, the corrosion inhibitor is sodium hexametaphosphate (SHMP).
In an embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is present in an amount in the range of 0 mass% to 1 mass% based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is present in an amount of 0.5 mass% based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is selected from the group consisting of non-ionic urethane associative thickener, and solvent-free and APEO-free HEUR thickener. In an exemplary embodiment of the present disclosure, the hydrophobically modified ethylene oxide urethane (HEUR) thickener is a non-ionic urethane associative thickener.
In an embodiment of the present disclosure, the predetermined amount of adhesion promoter is in the range of 0 mass % to 0.5 mass % based on the total mass of the composition of joint compound. In an exemplary embodiment of the present disclosure, the predetermined amount of adhesion promoter is 0.05 mass % based on the total mass of the composition of joint compound.
In an embodiment of the present disclosure, the adhesion promoter is selected from the group consisting of epoxy functional silane, beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (silquest 187), and beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (LX-A-11933). In an exemplary embodiment of the present disclosure, the adhesion promoter is beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane (silquest 187).
In an embodiment of the present disclosure, the stirring speed is in the range of 20 rpm to 50 rpm. In an exemplary embodiment of the present disclosure, the stirring speed is 35 rpm.
In an embodiment of the present disclosure, the fifth predetermined time period is in the range of 5 minutes to 20 minutes. In an exemplary embodiment of the present disclosure, the fifth predetermined time period is 15 minutes.
Still in another aspect, the present disclosure provides a method for applying a composition of joint compound on a substrate such as cement boards, calcium silicate board, gypsum board, and the like. The method comprises the following steps:
• pretreating a surface of the substrate to obtain a surface pretreated substrate; and
• filling the composition of joint compound between the surface pretreated substrates followed by drying for 6 hours to 12 hours to obtain joined substrates.
In an embodiment of the present disclosure, the substrate is selected from the group consisting of cement boards, calcium silicate board, gypsum board. In an exemplary embodiment of the present disclosure, the substrate is cement boards.
The surface on which the composition of joint compound is to be applied must be structurally sound and clean, free of oil, grease, wax, dust, sand, dirt, laitance, paints, e?lorescence, curing compounds, and loose materials of any type.
In an embodiment of the present disclosure, the composition of joint compound is diluted with water before applying on the substrate.
In an embodiment of the present disclosure, the composition of joint compound is applied by using a putty knife.
In an embodiment of the present disclosure, the composition of joint compound is used for joining the substrates, finishing the substrate, and filling the gaps formed in the substrate.
In an embodiment of the present disclosure, the excess composition of joint compound is removed from the surface of the substrate.
In an embodiment of the present disclosure, the drying time depend on weather and surface conditions.
In an embodiment of the present disclosure, the further coating systems is applied on the joint formed between the substrates/finish substrates.
The composition of joint compound of the present disclosure is used for interior concrete surfaces and exterior concrete surfaces. The composition of joint compound is used for joining boards such as cement boards/calcium silicate board, gypsum board, and the like.
The number of coats required by using the composition of joint compound of the present disclosure is less as compared to the coats required by using the conventional composition of joint compounds. Further, the composition of joint compound can withstand vibrations without developing cracks.
In an embodiment of the present disclosure, it is ensured that the joints/gaps are completely filled by the composition of joint compound.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment 1: Process for the preparation of the composition of joint compound in accordance with the present disclosure (without optional ingredients).
17 kg of water was charged in a ribbon blender and was mixed with 0.5 kg of predetermined amount of aqueous formulation of isothiazolinones, glycols and formaldehyde (preservatives), and 0.5 kg of organically modified bentonite (clay based thickeners) under at a speed of 35 rpm at temperature of 35 °C (room temperature) for a time period of 15 minutes (first predetermined time period) to obtain a first mixture in the form of a gelly.
In the obtained first mixture, 0.5 kg of monoethanolamine (pH stabilizer), 0.5 kg of sodium salt of carboxylic acid (dispersing agent), 0.5 kg of alkyl polyethylene glycol ether with 40 mole ethylene oxide (wetting agent), 0.5 kg of hydrocarbon oil based defoaming agent, and 0.6 kg of diethylene glycol (anti-freezing agent) were mixed at speed of 35 rpm for a time period of 7 minutes (second predetermined time period) to obtain a second mixture.
In the second mixture, 65 kg of dolomite powder (extender) was added under stirring at a speed of 35 rpm for a time period of 17 minutes (third predetermined time period) to obtain a third mixture.
6 kg of copolymer emulsion of vinyl acetate ethylene (VAE), 3 kg of copolymer emulsion styrene acrylic, 4 kg of co polymer emulsion acrylic (binder) was added to the third mixture under stirring at a speed of 35 rpm for a time period of 16 minutes (fourth predetermined time period) to obtain a fourth mixture.
In the so obtained fourth mixture, 0.5 kg of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (coalescing agent), 0.4 kg of polypropylene fiber (reinforcing agent) and 0.5 kg of aqueous alkylphenol ethoxylates (acrylic thickener) was added to the fourth mixture under stirring at a speed of 35 rpm for a time period of 15 minutes (fifth predetermined time period) to obtain the composition of joint compound.
Experiment 2: Process for the preparation of the composition of joint compound in accordance with the present disclosure (with optional ingredients).
16 kg of water was charged in a ribbon blender and was mixed with 0.5 kg of predetermined amount of aqueous formulation of isothiazolinones, glycols and formaldehyde (preservatives), and 0.5 kg of organically modified bentonite (clay based thickeners) under stirring at a speed of 35 rpm at temperature of 35 °C (room temperature) for a time period of 15 minutes (first predetermined time period) to obtain a first mixture in the form of a gelly.
In the obtained first mixture, 0.5 kg of monoethanolamine (pH stabilizer), 0.5 kg of sodium salt of carboxylic acid (dispersing agent), 0.5kg of alkyl polyethylene glycol ether with 40 mole ethylene oxide (wetting agent), 0.5 kg of hydrocarbon oil based defoaming agent, and 0.6 kg of diethylene glycol (anti-freezing agent) were mixed at speed of 35 rpm for a time period of 7 minutes (second predetermined time period) to obtain a second mixture.
In the second mixture, 65 kg of dolomite powder (extender) was added under stirring at a speed of 35 rpm for a time period of 17 minutes (third predetermined time period) to obtain a third mixture.
6 kg of copolymer emulsion of vinyl acetate ethylene (VAE), 3 kg of copolymer emulsion styrene acrylic, 4 kg of co polymer emulsion acrylic (binder) was added to the third mixture under stirring at a speed of 35 rpm for a time period of 16 minutes (fourth predetermined time period) to obtain a fourth mixture.
In the so obtained fourth mixture, 0.5 kg of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester (coalescing agent), 0.4 kg of polypropylene fibers (reinforcing agent), 0.5 kg of aqueous alkylphenol ethoxylates (acrylic thickener), 0.6 kg of sodium hexametaphosphate (SHMP) (corrosion inhibitor), 0.5 kg of non-ionic urethane associative thickener (hydrophobically modified ethylene oxide urethane (HEUR) thickener) and 0.08 kg of epoxy functional silane (adhesion promotor) was added to the fourth mixture under stirring at a speed of 35 rpm for a time period of 15 minutes (fifth predetermined time period) to obtain the composition of joint compound.
Mechanical properties of the composition of joint compound prepared in accordance with the present disclosure.
Preparation of test samples:
Cement boards (substrate) were pretreated to obtain surface pretreated cement board. The composition of joint compound obtained in experiment 1 or 2 was filled between the surface pretreated cement boards followed by drying for 10 hours to obtain joined cement board.
Composition of joint compound of the present disclosure comprises fibre reinforcement which along with elastomeric emulsions creates a bond with cement boards for jointing.
The bond formed between cement boards was evaluated for mud crack test visually. The results are summarized in table 1.
Table 1.
Experiment Viscosity
(KU) Reinforcing tape Mud crack test
after 12 hour Mud crack test
after 24 hours
Experiment 1
(With composition of joint compound of the present disclosure) 360 Not required No crack formation No crack formation
Experiment 2
(With composition of joint compound of the present disclosure) 365 Not required No crack formation No crack formation
Comparative Experiment
(2 component system) --- Required Crack formation Crack formation
From table 1 it is observed that there was not crack formation in the joint obtained by using the joint compound of the present disclosure. Further, it was observed that the joint formed by using the joint compound of the present disclosure does not require reinforcement such as paper tape, fiber tape, and the like. Furthermore, the joint formed by using the jointing composition of the present disclosure can withstand vibrations without developing cracks.
In accordance with the present disclosure, the chemical adhesion occurs by the penetration of the joint compound into the pores and cavities of the substrate on which it is applied. On the other hand the conventional two component system cannot penetrate into the pores and cavities of the substrates thereby forming a loose bond.
Further, the molecular bonding occurs between the molecules of two separate surfaces, one surface is the surface of the joint compound and the other surface is of the substrate (cement board) on which it is applied. Furthermore, the cross-linkage of polymer chains (binder) occurs between the joint compound and the substrate (Board) that is connected to each other by covalent bonds. These bonds create a sturdy three-dimensional network, and rigidity to the surface. The binders used in the composition of the joint compound crosslinks with the fibers present in the substrates (boards/panels such as Gypsum/Calcium silicate /Fiber Cement) and terminates the crack development. It forms one integrated strong bond by providing stability to the dimension of the substrate.
The conventional two component system requires to be mixed in a specific proportion to obtain a paste at the time of application. Moreover, the paste should be used within 15 minutes to 30 minutes or else it gets cured and hard. Whereas, the joint compound of the present disclosure is a ready to use composition that improves structural integrity and adhesion with the substrates which in return gives smooth texture to the substrates.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of:
? a composition of joint compound that:
• can join boards (such as cement boards, calcium silicate boards, gypsum boards);
• do not require reinforcement such as paper tape, fiber tape, and the like;
• can withstand vibrations without developing cracks;
• do not require multiple coats;
• is easy to apply;
• have no (zero) wastage;
• is non-toxic; and
• is economical.
and
? a process for the preparation of a composition of joint compound that;
• is simple and economical.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising, will be understood to imply the inclusion of a stated element, integer or step,” or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

CLAIMS:WE CLAIM:

1. A composition of joint compound comprising:
i) a predetermined amount of at least one binder;
ii) a predetermined amount of an extender;
iii) a predetermined amount of at least one thickener;
iv) a predetermined amount of at least one reinforcing agent;
v) a predetermined amount of at least one additive;
vi) q.s water;
vii) optionally a predetermined amount of at least one adhesion promoter; and
viii) optionally a predetermined amount of at least one corrosion inhibitor.
2. The composition as claimed in claim 1, wherein
i) said predetermined amount of said binder is in the range of 5 mass% to 30 mass%;
ii) said predetermined amount of said extender is in the range of 50 mass% to 70 mass%;
iii) said predetermined amount of said thickener is in the range of 0.1 mass% to 5 mass%;
iv) said predetermined amount of said reinforcing agent is in the range of 0.2 mass% to 2 mass%;
v) said predetermined amount of said additive is in the range of 1 mass% to 10 mass%;
vi) said predetermined amount of said adhesion promoter is in the range of 0 mass % to 0.5 mass %; and
vii) said predetermined amount of said corrosion inhibitor is in the range of 0 mass% to 2 mass%;
wherein mass% of each ingredient is with respect to total mass of said composition of joint compound.
3. The composition as claimed in claim 1, wherein a ratio of said binder to said extender is in the range of 1:2 to 1:10.
4. The composition as claimed in claim 1, wherein
(i) said binder is selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion;
(ii) said extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder;
(iii) said thickener is selected from the group consisting of clay based thickeners, acrylic thickeners, and optionally hydrophobically modified ethylene oxide urethane (HEUR) thickener;
(iv) said additive is selected from the group consisting of a dispersing agent, a wetting agent, a pH stabilizer, a defoaming agent, an anti-freezing agent, a preservative, and a coalescing agent;
(v) said reinforcing agent is selected from polypropylene fiber and acrylic fiber;
(vi) said adhesion promoter is selected from the group consisting of epoxy functional silane, beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane, and beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane; and
(vii) said corrosion inhibitor is sodium hexametaphosphate (SHMP).
5. The composition as claimed in claim 1, wherein said composition is characterized by having a viscosity in the range of 350 KU to 370 KU.
6. A process for preparation of the composition of joint compound as claimed in claim 1, said process comprising the following steps:
i) mixing predetermined amount of water, a predetermined amount of preservatives, and a predetermined amount of clay based thickeners in a blender under stirring at temperature in the range of 25 °C to 40 °C for a first predetermined time period to obtain a first mixture;
ii) adding a predetermined amounts of pH stabilizer, dispersing agent, wetting agent, defoaming agent, and anti-freezing agent to the first mixture under stirring for a second predetermined time period to obtain a second mixture;
iii) adding a predetermined amount of an extender to the second mixture under stirring at a third predetermined speed for a third predetermined time period to obtain a third mixture;
iv) adding a predetermined amount of a binder to the third mixture under stirring at a fourth predetermined speed for a fourth predetermined time period to obtain a fourth mixture; and
v) adding predetermined amounts of coalescing agent, acrylic thickener, reinforcing agent, optionally corrosion inhibitor, HEUR, and adhesion promotor in said fourth mixture under stirring at a fifth predetermined speed for a fifth predetermined time period to obtain said composition of joint compound.
7. The process as claimed in claim 6, wherein
• said predetermined amount of water is in the range of 5 mass % to 25 mass with respect to the total mass of said composition of joint compound;
• said predetermined amount of preservative is in the range of 0.1 mass % to 1 mass% with respect to the total mass of said composition of joint compound;
said preservative is selected from the group consisting of aqueous formulation of isothiazolinones, aqueous formulation of glycol, aqueous formulation of formaldehyde, (ethylenedioxy)dimethanol, 5-Chloro-2-methyl-2,3-dihydroisothiazol-3-one, 2-Methyl-2,3-dihydroisothiazol-3-one;
• said predetermined amount of clay based thickeners is in the range of 0.1 mass % to 2 mass% with respect to the total mass of said composition of joint compound;
said clay based thickener is selected from the group consisting of organically modified bentonite based rheological additive for water based system, and bentonite;
• said stirring is in the range of 20 rpm to 50 rpm; and
• said first predetermined time period is in the range of 10 minutes to 20 minutes.
8. The process as claimed in claim 6, wherein
• said predetermined amount of said pH stabilizer is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
• said pH stabilizer is selected from the group consisting of monoethanolamine, and 2-aminoethanol;
• said predetermined amount of said dispersing agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
said dispersing agent is selected from the group consisting of sodium salt of carboxylic acid and polyacrylate sodium salt;
• said predetermined amount of said wetting agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
said wetting agent is selected from the group alkyl polyethylene glycol ether with 40 mole ethylene oxide and ethylene oxide condensate of alkyl phenol;
• said predetermined amount of said defoaming agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
said defoaming agent is selected from the group consisting of hydrocarbon oil based antifoaming agent, and silicone oil;
• said predetermined amount of said anti-freezing agent is present in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
said anti-freezing agent is selected from the group consisting of diethylene glycol, monoethylene glycol and polypropylene glycol and
• said second predetermined time period is in the range of 5 minutes to 10 minutes.
9. The process as claimed in claim 6, wherein
• said extender is selected from the group consisting of dolomite powder, calcite powder, talc powder, mica powder, and china clay powder;
• said predetermined amount of said predetermined amount of extender is in the range of 50 mass% to 70 mass% based on the total mass of said composition of joint compound; and
• said third predetermined time period is in the range of 15 minutes to 20 minutes.
10. The process as claimed in claim 6, wherein
• said predetermined amount of said binder is in the range of 5 mass% to 30 mass% based on the total mass of said composition of joint compound;
• said binder is selected from the group consisting of copolymer emulsion of vinyl acetate ethylene (VAE), copolymer emulsion of styrene acrylic, and copolymer acrylic emulsion; and
• said fourth predetermined time period is in the range of 15 minutes to 20 minutes.
11. The process as claimed in claim 6, wherein
(i) said predetermined amount of said coalescing agent is in an amount in the range of 0.1 mass% to 1 mass% based on the total mass of said composition of joint compound;
(ii) said coalescing agent is selected from the group consisting of isobutyric acid 3-Hydroxy-2,2,4-trimethylpentyl ester and 2,2,4-trimethyl-1,3-pentanediol diisobutyrate;
(iii) said acrylic thickener is selected from the group consisting of aqueous alkylphenol ethoxylates, formaldehyde free acidic cross-linked acrylic thickener and anionic cross-linked acrylic copolymer emulsion;
(iv) said predetermined amount of said acrylic thickener is in an amount in the range of 0.1 mass% to 2 mass% based on the total mass of said composition of joint compound;
(v) said adhesion promoter is selected from the group consisting of epoxy functional silane, and beta-(3,4-epoxycyclohexyl)ethyl trimethoxy silane;
(vi) said predetermined amount of said adhesion promotor is in an amount in the range of 0 mass % to 0.5 mass % based on the total mass of said composition of joint compound; and
(vii) said fifth predetermined time period is in the range of 5 minutes to 20 minutes.

Dated this 9th day of August, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI