U.S. patent application number 09/923318 was filed with the patent office on 2001-12-20 for adhesive caulking material which can mimic the appearance of a multicolored stone surface.
This patent application is currently assigned to Gloucester Co., Inc.. Invention is credited to Anderson, Theodore P., Boise, Lawrence H., Modrak, Robert G..
Application Number | 20010053809 09/923318 |
Document ID | / |
Family ID | 22994677 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010053809 |
Kind Code |
A1 |
Anderson, Theodore P. ; et
al. |
December 20, 2001 |
Adhesive caulking material which can mimic the appearance of a
multicolored stone surface
Abstract
An adhesive caulking material comprising granular solid colored
particles dispersed in a base formulation is disclosed. The
adhesive caulking material exhibits a cosmetic capacity to take on
the appearance of a natural or synthetic solid substrate. A method
is provided for producing the adhesive caulking material comprising
the steps of: (a) providing a base formulation exhibiting a desired
background color; and (b) adding to the base formulation an amount
of granular solid colored particles effective to achieve a desired
appearance. The invention also relates to colored solid chips
comprising a coagulated or aggregated mixture comprising a
polymeric resin and an amount of one or more pigments sufficient to
obtain a desired single- or multi-colored appearance. The chips
have a granular shape and have a size in the range from about 0.25
mm to about 20 mm in diameter. A solid material is also described
which comprises: (a) a solid substrate comprising a plurality of
sections with gaps therebetween; the substrate having a speckled or
grainy appearance; and (b) a curable adhesive caulking material
comprising granular solid colored particles dispersed in a base
formulation, the adhesive caulking material substantially filling
the gaps and essentially matching the appearance of the
substrate.
Inventors: |
Anderson, Theodore P.;
(Uxbridge, MA) ; Boise, Lawrence H.; (Derry,
NH) ; Modrak, Robert G.; (Franklin, MA) |
Correspondence
Address: |
Pepper Hamilton LLP
600 Fourteenth Street, N.W.
Washington
DC
20005
US
|
Assignee: |
Gloucester Co., Inc.
Franklin
MA
|
Family ID: |
22994677 |
Appl. No.: |
09/923318 |
Filed: |
August 8, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09923318 |
Aug 8, 2001 |
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09614924 |
Jul 12, 2000 |
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09614924 |
Jul 12, 2000 |
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09261744 |
Mar 3, 1999 |
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6147149 |
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Current U.S.
Class: |
524/431 ;
524/430 |
Current CPC
Class: |
C09J 11/00 20130101;
Y10T 428/31826 20150401; Y10T 428/31855 20150401; Y10T 428/2982
20150115; C08K 3/22 20130101 |
Class at
Publication: |
524/431 ;
524/430 |
International
Class: |
C08K 003/18; C08K
003/22 |
Claims
What is claimed is:
1. Granular solid colored chips comprising a coagulated or
aggregated mixture comprising a polymeric resin and an amount of
one or more pigments sufficient to obtain a desired single- or
multi-colored appearance, said chips having a granular shape and
having a size ranging from about 0.25 mm to about 20 mm in
diameter.
2. The granular solid colored chips of claim 1 in which said
polymeric resin comprises a water-based resin selected from
acrylic, styrene-acrylic, styrene-butadiene, ethylene vinyl
acetate, vinyl acetate, or urethane resins.
3. The granular solid colored chips of claim 1 in which said one or
more pigments is selected from iron oxides, titanium dioxide,
chromium oxides and organic pigments.
4. The granular solid colored chips of claim 1 in which said
coagulated or aggregated mixture further comprises a surface-active
agent.
5. A process for the preparation of granular solid colored chips
comprising: (a) mixing a polymeric resin and one or more pigments
or pigment dispersions until a substantially uniformly dispersed
resin mixture is obtained; and (b) adding said substantially
uniformly dispersed resin mixture to a stirred salt solution at an
addition rate effective to provide a coagulated or aggregated
pigmented resin mixture containing solid colored chips having a
granular shape, a majority of which granular solid colored chips
having a diameter falling within a desired range.
6. The process of claim 5 which further comprises mixing a
surface-active agent with said coagulated or aggregated pigmented
resin mixture.
7. The process of claim 6 which further comprises separating said
granular solid colored chips into at least two separate portions
according to size.
8. The process of claim 7 in which said separation step includes
straining said granular solid colored chips through one or more
screens.
9. The process of claim 7 which further comprises washing at least
one of said portions to remove excess pigment.
10. The process of claim 9 in which said granular solid colored
chips are stored under water.
11. An adhesive caulking material comprising granular solid colored
particles dispersed in a base formulation, which adhesive caulking
material exhibits a cosmetic capacity to take on the appearance of
a natural or synthetic solid substrate.
12. The adhesive caulking material of claim 11 which exhibits on a
single- or multi-colored aggregate appearance.
13. The adhesive caulking material of claim 12 in which said
granular solid colored particles have a size ranging from about
0.25 mm to about 20 mm in diameter.
14. The adhesive caulking material of claim 11 which takes on the
appearance of a solid granite surface or a solid sandstone
surface.
15. The adhesive caulking material of claim 11 in which said base
formulation comprises a water-based synthetic polymeric resin.
16. The adhesive caulking material of claim 11 in which said base
formulation comprises a non-water based polymeric resin.
17. The adhesive caulking material of claim 16 in which the
polymeric resin comprises a non-water-based resin selected from
silicone, urethane, natural rubber, synthetic rubber, or
combinations thereof.
18. The adhesive caulking material of claim 17 in which the
silicone comprises acetoxy cures or non-acetoxy cures; the urethane
comprises single-component urethanes or multi-component urethanes;
the rubber comprises natural rubber, styrene butadiene rubber, or
polychloroprene.
19. The adhesive caulking material of claim 11 in which the
polymeric resin comprises a fluoroelastomer resin, silicone resins,
or combinations thereof.
20. The adhesive caulking material of claim 11 in which said
granular solid colored particles comprise granulated colored solid
chips, granulated pigmented polymeric aggregates, granulated,
shredded, or ground pieces of rubber or used tires, or colored
chunks or granules of plastic.
21. The adhesive caulking material of claim 20 in which said
granular solid colored particles have a size ranging from about 0.5
mm to about 13 mm in diameter.
22. The adhesive caulking material of claim 21 in which said
granular solid colored particles comprise ground recycled tires or
chunks of colored plastic.
23. A method for producing an adhesive caulking material comprising
granular solid colored particles dispersed in a base formulation;
said method comprising: (a) providing a base formulation exhibiting
a desired background color; and (b) adding to said base formulation
an amount of granular solid colored particles effective to achieve
a desired appearance.
24. The method of claim 23 which further comprises preparing said
base formulation by a process comprising: (a) adding one or more
pigments to an aqueous mixture of a polymeric resin to provide a
desired background color; (b) adding a desired amount of a
surface-active agent to the mixture of step (a); and (c) mixing the
surface-active agent-treated mixture of step (b) for a period of
time sufficient to provide a substantially uniformly colored base
formulation.
25. The method of claim 24 which further comprises preparing said
aqueous mixture of polymeric resin by a process comprising: (a)
combining an aqueous mixture of a water-based polymeric resin with
a plasticizer, a coalescing solvent, a surface-active agent and a
thickening agent; and (b) mixing the mixture of step (a) for a
period of time sufficient to provide a smooth consistency.
26. The method of claim 25 which further comprises addition of a
biocide and a blueing agent to the water-based polymeric resin.
27. The method of claim 23 which further comprises (c) adding a
filler to the mixture of step (b).
28. The method of claim 27 in which said filler is selected from a
talc, silica, clay and calcium carbonate.
29. The method of claim 27 which further comprises removing air
from the mixture of step (c) for a period of time effective to
provide an adhesive caulking material that exhibits a cosmetic
capacity to take on the appearance of a natural or synthetic solid
surface.
30. The method of claim 23 which further comprises preparing said
base formulation by a process comprising: (a) providing a
non-aqueous-based base formulation and, optionally, adding to the
non-aqueous-based base formulation one or more pigments to provide
a desired background color; (b) optionally adding a desired amount
of a surface-active agent to the mixture of step (a); and (c)
mixing the mixture of either step (a) or step (b) for a period of
time sufficient to provide a substantially uniformly colored base
formulation.
31. A solid material comprising: (a) a solid substrate comprising a
plurality of sections with gaps therebetween; said substrate having
a speckled or grainy appearance; and (b) a curable adhesive
caulking material comprising granular solid colored particles
dispersed in a base formulation, said adhesive caulking material
substantially filling said gaps and essentially matching said
speckled or grainy appearance.
32. A method of repairing a damaged natural or synthetic solid
substrate comprising applying in, on, or about the damaged area an
effective amount of an adhesive caulking material comprising
granular solid colored particles dispersed in a base formulation,
which adhesive caulking material exhibits a cosmetic capacity to
take on the appearance of a natural or synthetic solid
substrate.
33. The method of claim 32 in which the damage comprises a chip,
crack, or break.
Description
RELATED APPLICATION
[0001] The present application claims the benefit of the priority
date of earlier-filed and co-pending U.S. application Ser. No.
09/134,515, filed Aug. 14, 1998, which has been converted to a
provisional application under the provisions of 37 C.F.R..sctn.
1.53(c)(2).
FIELD OF THE INVENTION
[0002] This invention relates to an adhesive caulking material
containing solid colored particles dispersed in a base formulation.
The caulking material has the capacity to take on the appearance of
natural or synthetic solid substrates, including igneous or
metamorphic stone. This invention also relates to solid colored
chips used in the caulking material.
BACKGROUND OF THE INVENTION
[0003] Caulking compositions are known that are colored to match
existing solid surfaces. For example, U.S. Pat. Nos. 5,674,337 and
5,044,758 disclose addition of pigments to caulk compositions to
produce colored caulking material having an essentially homogeneous
appearance. These references do not suggest a caulking material
which can take on the appearance of a variety of solid
surfaces.
[0004] U.S. Pat. No. 5,229,439, granted to Gueret, discloses a
molded article having the appearance of natural stone. A
heat-setting resin, such as a urea formaldehyde resin, is mixed
with natural fibers or mineral filler. This mixture is then
compressed at high temperature and pressure in a mold to produce a
solid part with a natural stone appearance. Gueret mentions only
molded articles, and does not suggest that a natural stone
appearance could be obtained in any other way. No mention is made
of any pigment particles other than mineral fillers. Gueret does
not suggest production of a caulk having the appearance of natural
stone by incorporating pigment particles into a caulking or sealing
compound.
[0005] A caulking composition having the capacity to match the
appearance of a variety of surfaces, including natural stone
surfaces would be useful in sealing or repair of natural or
synthetic stone counter-tops and other substrates having a speckled
or grainy appearance.
[0006] Solid colored particles derived from polymeric resins are
disclosed in U.S. Pat. Nos. 5,106,889 and 4,166,811, granted to
Hirata et al. and Marr et al., respectively. Hirata et al. describe
production of particles by coagulation of a dispersion containing
pigment and a resin onto particles of polyvinyl chloride. In one
example, the resin is an acrylic resin, which is coagulated by
addition of calcium chloride. However, Hirata et al. do not prepare
any colored particles larger than 200 .mu.m, i.e., 0.2 mm, and do
not suggest that colored particles could be produced without using
a polyvinyl chloride core. In Marr et al., a pigment-resin
composite is produced from a dispersion of pigment and an acrylic
resin by acidifying the mixture to coagulate the resin. Neither
reference suggests that colored particles can be produced by
coagulation of a mixture of an acrylic resin and pigment by
addition of a metal salt.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to an adhesive caulking
material comprising granular solid colored particles dispersed in a
base formulation. The adhesive caulking material exhibits a
cosmetic capacity to take on the appearance of a natural or
synthetic solid substrate. The term "adhesive caulking material" is
meant to include an adhesive caulk, caulk, sealant, or like
material.
[0008] The invention is further directed to a method for producing
the adhesive caulking material by: (a) providing a base formulation
exhibiting a desired background color; and (b) adding to the base
formulation an amount of granular solid colored particles effective
to achieve a desired appearance.
[0009] The invention is still further directed to colored solid
chips comprising a coagulated or aggregated mixture comprising a
polymeric resin and an amount of one or more pigments sufficient to
obtain a desired single- or multi-colored appearance. The chips
have a granular shape and have a size in the range from about 0.25
mm to about 20 mm in diameter.
[0010] The invention is also directed to a process for the
preparation of granular solid colored chips comprising: (a) mixing
a polymeric resin and one or more pigments until a substantially
uniformly dispersed resin mixture is obtained; and (b) adding the
resin mixture to a stirred salt solution at an addition rate
effective to provide a coagulated or aggregated pigmented resin
mixture containing granular solid colored chips having a granular
shape, a majority of which granular solid colored chips having a
diameter falling within a desired range.
[0011] The invention is also directed to a solid material
comprising: (a) a solid substrate comprising a plurality of
sections with gaps therebetween; the substrate having a speckled or
grainy appearance; and (b) a cured or curable adhesive caulking
material comprising granular solid colored particles dispersed in a
base formulation, the adhesive caulking material substantially
filling the gaps and essentially matching the appearance of the
substrate.
[0012] The adhesive caulking material of the present invention may
have a variety of pigments optionally added to it. In addition, a
wide variety of base formulations are suitable for use in same, as
would be apparent to those of ordinary skill in the art after due
consideration of the disclosure provided herein. In particular, the
base formulation may be aqueous-based or non-aqueous-based, with
the resulting caulk preparations finding application in a wide
variety of environments, as discussed further below.
[0013] The present invention allows a new way of designing solid
surfaces in which substantially no gaps between, for example, tiles
or sections of the solid surfaces can be perceived due to the
substantial matching of the appearance of the natural or synthetic
solid surface by the adhesive caulking material disclosed herein.
Moreover, the invention also provides a method of repairing a
damaged natural or synthetic solid substrate comprising applying
in, on, or about the damaged area an effective amount of an
adhesive caulking material comprising granular solid colored
particles dispersed in a base formulation. Once again, because of
the cosmetic capacity exhibited by the adhesive caulking material,
the repaired area takes on the appearance of the natural or
synthetic solid substrate. A variety of damages to the solid
substrate can be repaired, including but not limited to chips,
cracks, or breaks in, on, or about the solid substrate.
[0014] A more detailed discussion of the present invention is
presented below, which is intended to provide additional
illustrations of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The adhesive caulking material of this invention comprises a
base formulation and granular solid colored particles. This
material can take on the appearance of a natural or synthetic solid
substrate having gradations in color, brightness, or both, which
lend a speckled or grainy appearance to the substrate. The natural
or synthetic solid substrate is a solid surface material, a
composite laminate material, such as FORMICA, tile, wood, coral,
natural igneous or sedimentary stone, including granite, sandstone
and quartz, or synthetic stone having the appearance of igneous or
sedimentary stone. A solid surface material is one which is uniform
in color and texture, so that a scratch in the surface does not
uncover material having a different color or texture. In preferred
embodiments of this invention, the adhesive caulking material takes
on the appearance of a single- or multi-colored aggregate substrate
having areas of different color and/or brightness from the
background area, e.g., granite, sandstone or coral. The natural or
synthetic solid substrate (or solid material, as the case may be)
can be part of a floor, wall, ceiling, counter top, back splash,
bath tub, shower, sink, bar or decorative facade.
[0016] When the caulking material of this invention is used to fill
gaps between sections of these substrates, the combination of the
substrate and the cured or curable caulk in the gaps comprises a
new surface having an appearance heretofore unattainable. The gaps
between sections are of a size usually encountered in construction,
and commonly filled in with a caulking material. For example, a
wall or floor constructed from tiles having a speckled or grainy
appearance, e.g., the appearance of granite or sandstone, comprises
substrate sections (the tiles) with relatively narrow gaps
therebetween. When these gaps are filled with the caulk of this
invention, formulated to match the appearance of the tiles, the
surface comprising the substrate sections and the cured caulk has
an essentially uniform appearance. If conventional caulk having a
homogeneous appearance had been used, the cured caulk in the gaps
would have a very different appearance from the substrate sections.
With conventional technology, the only way to achieve an
essentially uniform appearance was to install a single large piece
of the substrate, obviously an expensive and inconvenient
solution.
[0017] The base formulation is produced, for example, by adding
pigment or filler to an aqueous mixture of a polymeric resin
(including but not limited to acrylics, styrenes, styrene-acrylics,
styrene-butadienes, vinyl acetates, ethylene-vinyl acetates,
siliconized resins (e.g., silanes), urethanes and the like), then
adding a surface-active agent and mixing for a time sufficient to
provide a substantially uniform base formulation. Optionally, the
pigment or filler imparts a color to the base formulation which
aids in matching a particular surface. Preferably, the desired
aqueous mixture of polymeric resin is produced by combining a
water-based polymeric resin with a plasticizer, a coalescing
solvent, a surface-active agent and a thickening agent, and mixing
until a smooth consistency is obtained. Optionally, a biocide and a
blueing agent are also added to the mixture. Suitable plasticizers
include, without limitation, phthalates, dibenzoates and polymeric
plasticizers such as Rohm & Haas WP-1 and K-Flex DP. Suitable
coalescing solvents include, without limitation, ethylene glycol
ethers, diethylene glycol ethers, propylene glycol ethers,
dipropylene glycol ethers, hexylene glycol, n-butyl acetate and
mono-isobutyrates. Suitable biocides include, without limitation,
tributyltin salicylate, isothiazolinones and metal compounds having
biocidal activity. Preferred biocides are Troysan Polyphase P-20-T,
Kathon LX and Skane M-8. Suitable blueing agents include, without
limitation, fluorescent brighteners well known in the art. The
preferred blueing agent is Stilbene Fluorescent Brightener or
Leucophor C-7002U. Suitable surface-active agents include, without
limitation, well-known surfactants including sodium salts of
organic carboxylic acids including sodium lauryl sulfate, potassium
tripolyphosphate, petroleum-based defoamers and
octylphenoxypolyethoxyethanol. Preferred surfaceactive agents are
Foamaster 111 and Foamkill 639 J-OH. Suitable thickening agents
include, without limitation, cellulosic thickening agents,
polymeric thickening agents and laponite clay. Preferred thickening
agents are Methocel 856 and ASE-60. Suitable fillers include,
without limitation, talc, clay, silica and calcium carbonate.
[0018] If desired the base formulation is prepared by adding
pigment or filler to a non-aqueous polymeric resin, or mixtures
thereof, and mixing for a time sufficient to provide a
substantially uniform base formulation. As in the aqueous-based
formulations, the optional pigment or filler imparts a color to the
non-aqueous-based base formulation, which aids in matching a
particular surface. A variety of non-aqueous resins can be used to
good advantage in the preparation of the caulking material of the
present invention. Preferred resins include, but are not limited
to; silicone resins (including, for example, acetoxy- and
non-acetoxy cured silicone resins), single- and multiple component
urethanes, natural and synthetic rubbers (such as styrene butadiene
rubber and polychloropren) and the like. Other suitable
non-aqueous-based resins include fluoroelastomers and, generally,
any non-aqueous-based resins that can be formulated with a suitable
pigment to provide the desired background color and which can be
further formulated with granular solid colored particles dispersed
therein. The resulting formulation may further include a number of
non-aqueous-based components, such as conventional silicone
caulks.
[0019] The wide variety of materials that can be incorporated into
the base formulations of the adhesive caulking material provides
great flexibility into the physical properties and characteristics
of the end product. In the case of a polyurethane resin, the base
formulation and resultant end product may be characterized as
durable, flexible, waterproof, and weather resistant. The adhesive
caulking material is completely odorless and contains no volatile
organic compounds. It adheres to cast iron and most other metals,
masonry, concrete glass, tile, vitreous china and porcelain. In the
case of a fluoroelastomer non-aqueous-based base formulation, the
resultant material is resistant to virtually all chemicals. Use of
a non-aqueous two-part epoxy sealing putty formulation provides an
adhesive caulking material that is electrically con-conductive and
which can be ground, filed, sanded, or drilled. What is more, the
adhesive caulking material having a silicone base is flexible,
durable, mildew-resistant, waterproof and suitable for interior or
exterior applications. Such an adhesive caulking material has
especially excellent adhesive and groundable properties when
applied to ceramic, metal, or plastic.
[0020] A very wide range of properties may also be obtained when a
non-aqueous polychloropren synthetic rubber is used in this
invention. The resulting adhesive caulking material can fall within
a wide range of crystallization rates and viscosity. The
crystallization rate determines the rate of initial strength
development, and the viscosity influences the inherent strength of
the resultant caulk. This synthetic rubber is oil resistant,
resists degradation from sun, ozone and outdoor weather, is
flexible over a wide temperature range, is very tough and resists
burning. Formulation of the adhesive caulk material using natural
rubber gives a product with different properties. This caulk has
excellent resilience and rebound, can be used at a wide temperature
range and has excellent adhesion to stone, ceramic, or metal
surfaces.
[0021] The granular solid colored particles employed in this
invention are selected from the granular solid colored chips of
this invention and solid colored aggregate. Substantially all of
the granular solid colored particles have a diameter after
screening ranging from about 0.25 mm to about 20 mm, preferably
from about 0.5 mm to about 13 mm. The diameter of the solid colored
particles varies depending on the appearance of the surface the
caulking material is intended to match. A surface having relatively
large areas of different color and/or brightness from the
background color or brightness is more closely matched by a caulk
containing relatively large colored particles. The granular solid
colored particles are flexible and pliant when mixed into the base
formulation and remain so after the caulking material cures in
place.
[0022] The granular solid colored chips of this invention comprise
a mixture of coagulated or aggregated polymeric resin and one or
more pigments which impart a single- or multi-colored appearance to
the particles. In one embodiment of the present invention, the
solid colored chips are produced by coagulation of a polymeric
resin containing a pigment. The pigment is selected from the
various colors of iron oxides, titanium dioxide, chromium oxides,
and the organic pigments. The pigment is added either in the form
of a solid pigment, or as a pigment dispersion well known to those
skilled in the art, e.g., a dispersion of a solid pigment in oil or
latex. Examples of pigments and dispersions suitable for use in
this invention, without limitation, are RHD6-X Titanium Dioxide,
Carmine Red W-3160 Dispersion, Chromium Oxide, Burnt Umber Iron
Oxide, Iron Oxide Yellow, Phthalocyanine Blue W-4124 Dispersion,
Phthalocyanine Green W-6013 Dispersion and Iron Oxide Black. In
another embodiment of the present invention, the solid colored
particles comprise solid colored aggregate, which is typically, but
not necessarily, recycled solid polymeric material that has been
granulated, shredded or ground. In a preferred embodiment of this
invention, the solid colored particles comprise granulated,
shredded or ground pieces of rubber or recycled tires.
[0023] The polymeric resin employed in production of the granular
solid colored chips is any resin that can be coagulated in the
presence of a pigment. The preferred resins are synthetic polymeric
resins, including acrylics, styrene-acrylics, styrene-butadienes,
vinyl acetates, ethylene-vinyl acetates, silicones and urethanes.
Especially preferred are the acrylic resins that can be coagulated
by the addition of a metal salt. The preferred metal salt is
calcium chloride. Typically, the resin in the form of an aqueous
emulsion is added to an aqueous solution of a metal salt at a rate
effective to provide a coagulated pigmented resin. The mixture is
stirred with a high-shear mixer. A surface-active agent is added to
the mixture and the mixture is stirred for a time sufficient to
provide granular solid colored chips, which are approximately in
the desired size range. The chips obtained from this process are
granular, i.e.; they are of irregular shape. If necessary, the
particles are separated according to size to produce particles
having the desired size range. A preferred method for separation
according to size is straining through a screen, or sequentially
straining through a plurality of screens having different opening
sizes. Particles collected on a screen may be washed to remove any
excess pigment. Preferably, hot water is used to wash the
particles. The colored chips of this invention remain pliable after
the caulking material is cured.
[0024] The following examples are presented in order to illustrate
various aspects of the present invention, but are not intended to
limit it.
EXAMPLES
[0025] 5.1. Production of Granular Solid Colored Chips
[0026] 5.1.1 Formation of Colored Chips
[0027] Rohm & Haas 1785 water-based resin (8.5 gallons, 32
liters) (available from Rohm & Haas Company, Philadelphia, Pa.)
is added to a large mixing drum, and the drum is placed under a
Cowles mixer (available from Morehouse Industries, Fullerton,
Calif.). The mixer is started at 1300 RPM and the appropriate
amount of pigment or dispersion is added to obtain the desired
color. When the contents of the drum are thoroughly mixed, the
mixer is turned off and the drum set aside.
[0028] Hot water (25 gallons, 94.5 liters) is added to a second
large mixing drum, and the drum is placed under a Cowles mixer. The
mixer is started at 1300 RPM. Calcium chloride (4.4 pounds, 2.0 kg)
is added to the water and the mixture is stirred for 5 minutes or
until all of the salt is dissolved.
[0029] While mixing is continued, the pigmented resin from the
set-aside drum is slowly added to the salt solution. The resin is
added carefully to avoid overly rapid coagulation, which can lead
to an undesirable increase in particle size. Just as the last of
the pigmented resin has been added to the salt solution, 180 g of
Foamaster 111 surface-active agent (available from Henkel Corp.,
Ambler, Pa.) is added. The mixture is stirred until the colored
chips are essentially in the desired size range, usually 5-10
minutes.
[0030] 5.1.2. Straining the Pigment Chips from the Salt
Solution
[0031] The pigmented chips are strained into a large drum covered
with a 1/4 inch (6.4 mm) metal screen to remove any oversize
particles. The oversize particles are retained for use in another
formula or discarded.
[0032] The pigmented chips from the drum are strained again into
another drum covered with a standard window screen to remove any
excess pigment. Hot water is used to flush the excess pigment from
the pigmented chips on the screen. The drum is used to reclaim the
salt solution and the excess pigment. As the screen fills up, the
chips are removed to a separate 5 gallon (19 liter) pail for
temporary or long-term storage under water. Continue until all
pigmented chips have been washed and stored in this manner. Chips
that are not used immediately are stored under water to prevent
agglomeration.
[0033] 5.2. Preparation of Standard Base Formula
[0034] As a standard water-based base formula, a translucent caulk
is used. Commercially available translucent caulks can be used,
such as Phenoseal.RTM. Vinyl Adhesive Caulk Translucent, which is
available from Gloucester Company, Inc., Franklin, Mass.
[0035] Alternatively, an aqueous-based base formula can be prepared
as follows: A 55 gallon (208 liter) drum is placed under a Cowles
mixer and about 15-20 gallons (68 liters) of a water-based resin
(e.g., CYP-101, available from Cypress Polymers, Inc., Babson Park,
Mass.) is added. The mixer is started at 1300 RPM. To the resin is
added about 1-5 gallons of plasticizer, about 1-5 gallons of
coalescing solvent, about 100-200 g of a preservative and about
1000-5000 g of a thickening agent. Optionally, about 100-200 g of a
blueing agent can be added, along with other optional ingredients,
such as about 200-500 g of a defoamer and about 2000-7000 g of
powdered silica. The resulting mixture is stirred until smooth.
[0036] Commercial plasticizers are available from Kalama Chemical,
Garfield, N.J., coalescing solvents from Monson, Leominster, Mass.,
preservatives from Troy Chemical, Newark, N.J., blueing agents from
Clariant Chemicals, Charlotte, N.C., defoamers from Henkel Corp.,
Ambler, Pa. and thickening agents from DOW Chemical, Midland, Mich.
Commercial powdered silica can obtained from North America Silica
Corp., Valley Forge, Pa.
[0037] In a preferred embodiment of the invention, the following
components (with approximate amounts indicated in parenthesis) are
mixed to produce the standard base formula: water-based resin (18
gallons or 68 liters); plasticizer (1.5 gallons or 5.7 liters);
coalescing solvent (1.8 gallons or 6.8 liters); preservative (135
g); optional blueing agent (164 g); optional defoamer or surface
active agent (235 g); thickening agent (1000-5000 g); and optional
powdered silica (4500 g).
[0038] 5.3. Preparation of Caulk
[0039] The drum of the preferred standard base formula mixture
prepared in Example 5.2, above, is transferred to a Myers Planetary
mixer (C. K. "Bud" Myers Engineering, Inc., Bell, Calif.). While
mixing, an appropriate amount of pigment is added to reach the
desired base background color. Foamaster 111 surface-active agent
(about 84 g) (available from Henkel Corp., Ambler, Pa.) is added,
and the contents of the drum are mixed until the color is uniform,
ca. 5-10 minutes. The sweeper blades are cleaned during the mixing
process to ensure that all pigment is incorporated into the
mixture.
[0040] An appropriate amount of pigmented chips produced in Example
5.1 is added to obtain the desired appearance; mixing is continued
for no more than about 5 minutes. Then, about 31 pounds (ca. 14 kg)
of IT-3X talc filler (available from R. T. Vanderbilt Co., Norwalk,
Conn.) and about 3.7 pounds (ca. 1.7 kg) of Sipemat 22 LS fumed
silica (available from North America Silica Corp., Valley Forge,
Pa.) are added and the contents mixed for 5 minutes. The sweeper
blades are cleaned during mixing to ensure complete incorporation
of filler.
[0041] The contents are then vacuum mixed at a minimum of 22 mm Hg
for 10 minutes to remove entrapped air from the contents. The drum
is removed from the Myers mixer.
[0042] 5.4. Use of Polyurethane Base Formulation
[0043] A non-aqueous-based (that is, non-water-based) base
formulation can also be used to good advantage in the preparation
of the adhesive caulking material of the present invention. In
particular, a polyurethane base formulation can be used. A
single-component polyurethane sealant, NEW PLASTIC SEAL (available
from Hercules Chemical Co, Inc., Passaic, N.J.), is substituted for
the base formula mixture of Example 5.2. The adhesive caulking
material of the present invention is then prepared as described in
Example 5.3.
[0044] 5.5. Use of Fluoroelastomer Base Formulation
[0045] A non-aqueous-based base formulation can also be used to
good advantage in the preparation of the adhesive caulking material
of the present invention. In particular, a fluoroelastomer base
formulation can be used. A single-component fluoroelastomer, VITON
(available from DuPont Dow Elastomers, L.L.C., Wilmington, Del.),
is substituted for the base formula mixture of Example 5.2. The
adhesive caulking material of the present invention is then
prepared as described in Example 5.3.
[0046] 5.6. Use of Silicone Base Formulation
[0047] A non-aqueous-based base formulation can also be used to
good advantage in the preparation of the adhesive caulking material
of the present invention. In particular, a silicone base
formulation can be used. A non-aqueous-based silicone base
formulation is available from Dow Coming, Co., Midland, Mich. This
caulk formulation, which is available in a variety of colors, is
substituted for the base formula mixture of Example 5.2. A clear
silicone base formulation can be colored by the addition of
pigments, as appropriate. The adhesive caulking material of the
present invention is then prepared as described in Example 5.3.
[0048] 5.7. Use of Epoxy Base Formulation
[0049] A two-part epoxy sealing putty base formulation, available
from Hercules Chemical Co, Inc., Passaic, N.J., which contains a
two-part component, is substituted for the base formula mixture of
Example 5.2. The adhesive caulking material of the present
invention is then prepared as described in Example 5.3. The
hardener component is added to the mixture and thoroughly mixed
just before the caulk is applied.
[0050] 5.8. Use of Synthetic Rubber Base Formulation
[0051] A non-aqueous based synthetic rubber base formulation can be
used to advantage in the present invention. A synthetic rubber,
polychloropren, is available from DuPont Dow Elastomers L.L.C.,
Wilmington, Del. The base formulation utilizing this synthetic
rubber is substituted for the base formula mixture of Example 5.2.
In particular, the synthetic rubber can be dissolved in a suitable
amount of toluene. Neoprene WHVA is a special grade of neoprene
with a moderate crystallization rate and high viscosity. The
adhesive caulking material of the present invention is then
prepared as described in Example 5.3.
[0052] 5.9. Use of Natural Rubber Base Formulation
[0053] Natural rubber, also called polyisoprene, suitable for use
in a base formulation is available from Baxter Rubber Co.,
Fairfield, N.J. The rubber-base base formulation is substituted for
the base formula mixture of Example 5.2. The polyisoprene is
dissolved in an appropriate aromatic hydrocarbon, such as toluene,
before being added to the mixer. The adhesive caulking material of
the present invention is then prepared as described in Example
5.3.
[0054] The preceding Examples are intended to describe certain
preferred embodiments of the present invention. It should be
appreciated, however, that obvious additions and modifications of
the invention will be apparent to one skilled in the art. The
invention is not limited except as set forth in the claims.
* * * * *