U.S. patent application number 10/823419 was filed with the patent office on 2005-11-10 for system using a drywall board and a jointing compound.
Invention is credited to Bingaman, Andrew B., Colbert, Elizabeth, Domenech, Marc, Gagne, Pierre, Hedman, Goran, Jacquet, Stuart, O'Connor, Kenneth B..
Application Number | 20050246993 10/823419 |
Document ID | / |
Family ID | 35238166 |
Filed Date | 2005-11-10 |
United States Patent
Application |
20050246993 |
Kind Code |
A1 |
Colbert, Elizabeth ; et
al. |
November 10, 2005 |
System using a drywall board and a jointing compound
Abstract
Coating and jointing material systems for wall construction are
provided. The coating is applied to drywall elements prior to
installation and is compatible with the jointing materials such
that a substantially homogeneous surface may be obtained after the
drywall elements are assembled with jointing material and the
jointing material is dried. Methods for the construction of
interior walls and interior construction systems are provided.
Inventors: |
Colbert, Elizabeth; (Newark,
DE) ; Bingaman, Andrew B.; (Dillsburg, PA) ;
Domenech, Marc; (La Roque Sur Pernes, FR) ; Gagne,
Pierre; (Varennes, CA) ; O'Connor, Kenneth B.;
(Ashburn, VA) ; Hedman, Goran; (Rochefort du Gard,
FR) ; Jacquet, Stuart; (Cabries, FR) |
Correspondence
Address: |
BUCHANAN INGERSOLL PC
(INCLUDING BURNS, DOANE, SWECKER & MATHIS)
POST OFFICE BOX 1404
ALEXANDRIA
VA
22313-1404
US
|
Family ID: |
35238166 |
Appl. No.: |
10/823419 |
Filed: |
April 13, 2004 |
Current U.S.
Class: |
52/459 |
Current CPC
Class: |
C04B 26/06 20130101;
C04B 26/06 20130101; C04B 26/02 20130101; C04B 26/06 20130101; E04F
13/04 20130101; C04B 2103/44 20130101; C04B 14/042 20130101; C04B
14/10 20130101; C04B 14/28 20130101; C04B 24/2623 20130101; C04B
14/10 20130101; C04B 24/2623 20130101; C04B 24/38 20130101; C04B
14/20 20130101; C04B 14/042 20130101; C04B 14/28 20130101; C04B
24/383 20130101; C04B 24/38 20130101; C04B 14/10 20130101; C04B
14/10 20130101; C04B 14/20 20130101; C04B 24/42 20130101; C04B
14/26 20130101; C04B 2103/40 20130101; C04B 2103/408 20130101; C04B
2103/44 20130101; C04B 14/365 20130101; C04B 14/28 20130101; C04B
14/28 20130101; C04B 14/26 20130101; C04B 24/2641 20130101; C04B
2111/00146 20130101; C04B 2111/00482 20130101; C04B 14/365
20130101; C04B 24/2641 20130101; C04B 24/42 20130101; C04B
2111/00672 20130101; C04B 26/02 20130101; C04B 26/02 20130101 |
Class at
Publication: |
052/459 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. An interior construction system comprising: one or more
prefabricated drywall elements; at least one skim coat deposited on
the one or more prefabricated drywall elements from a coating
formulation comprising water, a binder, a mineral filler and a
noncellulosic thickener; and at least one jointing material for
assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, wherein the jointing material, when dry, substantially
matches the skim coat.
2. The system of claim 1, wherein the at least one jointing
material and at least one skim coat form a substantially
homogeneous outer surface on the substantially plane outer
surface.
3. The system of claim 1, wherein at least one of the parameters in
the group consisting of coloration, reflectance factor and surface
water absorption is substantially homogeneous over the
substantially plane outer surface.
4. The system of claim 1, wherein the at least one jointing
material and the at least one skim coat exhibit substantially the
same surface water absorption when dry.
5. The system of claim 3, wherein the surface water absorption, as
measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
6. The system of claim 1, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
7. The system of claim 6, wherein the anti-cracking agent is mica
and the workability agent is clay.
8. The system of claim 1, wherein the mineral filler comprises more
than about 60% calcium carbonate.
9. The system of claim 1, wherein the drywall elements are gypsum
wallboard.
10. A method for the construction of interior walls comprising:
assembling skim coated prefabricated drywall elements, wherein the
skim coated prefabricated drywall elements have a coating layer of
at least one skim coat deposited on the prefabricated elements by a
coating device, the skim coat formed from a coating formulation
comprising water, a binder, a mineral filler, and a noncellulosic
thickener; jointing adjacent prefabricated elements with at least
one jointing material wherein the jointing material, when dry,
substantially matches the skim coat; and drying the jointing
material.
11. The method of claim 10, wherein the at least one jointing
material and the at least one skim coat form, in the dry state, a
substantially homogeneous outer surface.
12. The method of claim 11, wherein at least one of the parameters
in the group consisting of coloration, reflectance factor and
surface water absorption is substantially homogeneous over the
substantially homogeneous outer surface.
13. The method of claim 10, wherein the at least one jointing
material and the at least one skim coat exhibit substantially the
same surface water absorption when dry.
14. The method of claim 12, wherein the surface water absorption,
as measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
15. The method of claim 10, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
16. The method of claim 15, wherein the anti-cracking agent is mica
and the workability agent is clay.
17. The method of claim 10, wherein the mineral filler comprises
more than about 60% calcium carbonate.
18. The method of claim 10, wherein the drywall elements are gypsum
wallboard.
19. An interior construction system comprising: one or more
prefabricated drywall elements; at least one skim coat deposited on
the one or more prefabricated drywall elements from a coating
formulation comprising water, a binder, a mineral filler and a
noncellulosic thickener; and at least one jointing material for
assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, the jointing material comprising substantially the same
solids as the coating formulation, wherein the amount of water in
the jointing material is from about 10% to about 60% less than the
amount of water in the coating formulation.
20. The system of claim 19, wherein the at least one jointing
material and at least one skim coat form a substantially
homogeneous outer surface on the substantially plane outer
surface.
21. The system of claim 19, wherein at least one of the parameters
in the group consisting of coloration, reflectance factor and
surface water absorption is substantially homogeneous over the
substantially plane outer surface.
22. The system of claim 19, wherein the at least one jointing
material and the at least one skim coat exhibit substantially the
same surface water absorption.
23. The system of claim 21, wherein the surface water absorption,
as measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
24. The system of claim 19, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
25. The system of claim 24, wherein the anti-cracking agent is mica
and the workability agent is clay.
26. The system of claim 19, wherein the mineral filler comprises
more than about 60% calcium carbonate.
27. The system of claim 19, wherein the drywall elements are gypsum
wallboard.
28. A method for the construction of interior walls comprising:
assembling skim coated prefabricated drywall elements, wherein the
skim coated prefabricated drywall elements have a coating layer of
at least one skim coat deposited on the prefabricated elements by a
coating device, the skim coat formed from a coating formulation
comprising water, a binder, a mineral filler, and a noncellulosic
thickener; jointing adjacent prefabricated elements with at least
one jointing material, the jointing material comprising
substantially the same solids as the coating formulation, wherein
the amount of water in the jointing material is from about 10% to
about 60% less than the amount of water in the coating formulation;
and drying the jointing material.
29. The method of claim 28, wherein the at least one jointing
material and the at least one skim coat form, in the dry state, a
substantially homogeneous outer surface.
30. The method of claim 29, wherein at least one of the parameters
in the group consisting of coloration, reflectance factor and
surface water absorption is substantially homogeneous over the
substantially homogeneous outer surface.
31. The method of claim 28, wherein the at least one jointing
material and the at least one skim coat exhibit substantially the
same surface water absorption when dry.
32. The method of claim 30, wherein the surface water absorption,
as measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
33. The method of claim 28, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
34. The method of claim 33, wherein the anti-cracking agent is mica
and the workability agent is clay.
35. The method of claim 28, wherein the mineral filler comprises
more than about 60% calcium carbonate.
36. The method of claim 28, wherein the drywall elements are gypsum
wallboard.
37. An interior construction system comprising: one or more
prefabricated drywall elements; at least one skim coat deposited on
the one or more prefabricated drywall elements from a coating
formulation comprising water, a binder, a mineral filler and a
noncellulosic thickener; and at least one jointing material for
assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, the jointing material comprising about 25 to about 45%
water, about 40 to about 70% of a mineral filler which is the same
or different from the mineral filler of the coating formulation,
about 1.0 to about 3.0% anti-cracking agent, about 1.0 to about
4.0% clay, about 0.1 to about 1.0% thickener and water retention
agent, about 1.0 to 5.0% talc, about 0.5 to about 3.0% of a binder
which is the same or different as the binder of the coating
formulation, and about 0.1 to about 1.0% starch.
38. The system of claim 37, wherein the at least one jointing
material and at least one skim coat form a substantially
homogeneous outer surface on the substantially plane outer
surface.
39. The system of claim 37, wherein the surface water absorption,
as measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
40. The system of claim 37, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
41. The system of claim 40, wherein the anti-cracking agent is mica
and the workability agent is clay.
42. The system of claim 37, wherein the mineral filler in each of
the coating formulation and the jointing material comprises more
than about 60% calcium carbonate.
43. The system of claim 37, wherein the thickener and water
retention agent in the jointing material comprises hydroxypropyl
methylcellulose.
44. The system of claim 37, wherein the binder in the coating
formulation and the binder in the jointing material is the
same.
45. The system of claim 43, wherein the binder in the jointing
material is an acrylic polymer.
46. The system of claim 37, wherein the drywall elements are gypsum
wallboard.
47. A method for the construction of interior walls comprising:
assembling skim coated prefabricated drywall elements, wherein the
skim coated prefabricated drywall elements have a coating layer of
at least one skim coat deposited on the prefabricated elements by a
coating device, the skim coat formed from a coating formulation
comprising water, a binder, a mineral filler, and a noncellulosic
thickener; jointing adjacent prefabricated elements with at least
one jointing material wherein the jointing material comprises about
25 to about 45% water, about 40 to about 70% of mineral filler
which is the same or different from the mineral filler of the
coating formulation, about 1.0 to about 3.0% anti-cracking agent,
about 1.0 to about 4.0% clay, about 0.1 to about 1.0% thickener and
water retention agent, about 1.0 to 5.0% talc, about 0.5 to about
3.0% of a binder which is the same or different as the binder of
the coating formulation, and about 0.1 to about 1.0% starch; and
drying the jointing material.
48. The method of claim 47, wherein the at least one jointing
material and the at least one skim coat form, in the dry state, a
substantially homogeneous outer surface.
49. The method of claim 47, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
50. The method of claim 49, wherein the anti-cracking agent is mica
and the workability agent is clay.
51. The method of claim 47, wherein the mineral filler in each of
the coating formulation and the jointing material comprises more
than about 60% calcium carbonate.
52. The method of claim 47, wherein the thickener and water
retention agent in the jointing material comprises hydroxypropyl
methylcellulose.
53. The method of claim 47, wherein the binder in the coating
formulation and the binder in the jointing material is the
same.
54. The method of claim 47, wherein the binder in the jointing
material is an acrylic polymer.
55. The method of claim 47, wherein the drywall elements are gypsum
wallboard.
56. An interior construction system comprising: one or more
prefabricated drywall elements; at least one skim coat deposited on
the one or more prefabricated drywall elements from a coating
formulation comprising water, a binder, a mineral filler and a
noncellulosic thickener; and at least one jointing material for
assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, wherein the jointing material comprises 50 to 85% of a
mineral filler which is the same or different from the mineral
filler of the coating formulation; 1 to 20% of an organic binder
dispersible in an aqueous phase; 1 to 15% of a silicate-based
agent; 0.2 to 5% of a hydrophobic agent which is a silicone
derivative; 0.05 to 5% of polyvinyl alcohol; and water to make up
to 100%.
57. The system of claim 56, wherein the at least one jointing
material and at least one skim coat form a substantially
homogeneous outer surface on the substantially plane outer
surface.
58. The system of claim 56, wherein the surface water absorption,
as measured by the drop test, is at least 45 minutes for both the
jointing material and the skim coat.
59. The system of claim 56, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
60. The system of claim 59, wherein the anti-cracking agent is mica
and the workability agent is clay.
61. The system of claim 56, wherein the mineral filler in the
coating formulation comprises more than about 60% calcium
carbonate.
62. The system of claim 56, wherein the drywall elements are gypsum
wallboard.
63. A method for the construction of interior walls comprising:
assembling skim coated prefabricated drywall elements, wherein the
skim coated prefabricated drywall elements have a coating layer of
at least one skim coat deposited on the prefabricated elements by a
coating device, the skim coat formed from a coating formulation
comprising water, a binder, a mineral filler, and a noncellulosic
thickener; jointing adjacent prefabricated elements with at least
one jointing material wherein the jointing material comprises 50 to
85% of a mineral filler which is the same or different from the
mineral filler of the coating formulation; 1 to 20% of an organic
binder dispersible in an aqueous phase; 1 to 15% of a
silicate-based agent; 0.2 to 5% of a hydrophobic agent which is a
silicone derivative; 0.05 to 5% of polyvinyl alcohol; and water to
make up to 100%; and drying the jointing material.
64. The method of claim 63, wherein the at least one jointing
material and the at least one skim coat form, in the dry state, a
substantially homogeneous outer surface.
65. The method of claim 63, wherein the coating formulation further
comprises about 0.5 to about 15.0% by weight dispersant, about 0.1
to about 20% by weight anti-cracking agent and about 0.1 to about
5% by weight workability agent.
66. The method of claim 65, wherein the anti-cracking agent is mica
and the workability agent is clay.
67. The method of claim 63, wherein the mineral filler in the
coating formulation comprises more than about 60% calcium
carbonate.
68. The method of claim 63, wherein the drywall elements are gypsum
wallboard.
Description
FIELD OF THE INVENTION
[0001] Compatible coating formulation and jointing material systems
for improved drywall installation are provided. A method for
constructing interior walls including applying the coating and
jointing material systems and interior construction systems formed
with the use of the coating and jointing materials are further
provided.
BACKGROUND
[0002] Interior walls typically are installed by use of flat,
prefabricated boards which are assembled with the use of jointing
material such as joint compounds, sealing coats, joint coats and/or
joint-pointing coats. The prefabricated elements can be gypsum
fiberboards, cement fiberboards, gypsum wallboards or plaster
boards and the like. The flat, prefabricated boards typically
include at least one sheet of lining paper, at least one outer
layer of which has a visible outer face ready to be decorated.
Generally, in the construction of interior walls, flat
prefabricated elements, or drywall elements, are fastened to wall
frames by, for example, nails or screws, and the joints taped or
plastered with a jointing material. The prefabricated elements are
assembled together, optionally with a jointing material and the
joints are finished with a sealing coat, joint coat and/or
joint-pointing coat, so as to obtain an overall visible outer
surface which is relatively uniform or plane, including in the
region of the joints.
[0003] After the interior assembly work has been completed, the
preparation generally involves covering the overall surface
obtained, i.e., the lining of the flat prefabricated elements plus
the joints, with one or more layers of a paint or priming or
finishing coat. The overall visible outer surface of the flat,
prefabricated boards typically needs to be prepared, before
receiving any surface decoration, such as by application of one or
more layers of a film covering of the paint or lacquer type or a
wallpaper. This preparation is necessitated especially by the shade
or color differences existing between the visible outer surface of
the flat prefabricated elements, for example plasterboards, and the
visible outer surface of the joints.
[0004] The preparation operation represents an appreciable
additional cost, for example in a complete process for the
construction of a building. And, in some cases, it is still
insufficient for obtaining an overall decorated surface of uniform
appearance, particularly in view of the physico-mechanical
differences prevailing between the joints and the flat
prefabricated elements.
SUMMARY
[0005] Systems for drywall application are provided which simplify
the installation of interior walls by substantially eliminating the
need for a final skim coat on the drywall. In one embodiment, an
interior construction system is provided comprising one or more
prefabricated drywall elements; at least one skim coat deposited on
the one or more prefabricated drywall elements from a coating
formulation comprising water, a binder, a mineral filler and a
noncellulosic thickener; and at least one jointing material for
assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, wherein the jointing material, when dry, substantially
matches the skim coat.
[0006] In a further embodiment, a method for the construction of
interior walls is provided comprising assembling skim coated
prefabricated drywall elements, wherein the skim coated
prefabricated drywall elements have a coating layer of at least one
skim coat deposited on the prefabricated elements by a coating
device, the skim coat formed from a coating formulation comprising
water, a binder, a mineral filler, and a noncellulosic thickener;
jointing adjacent prefabricated elements with at least one jointing
material wherein the jointing material, when dry, substantially
matches the skim coat; and drying the jointing material.
[0007] In a further embodiment, an interior construction system is
provided comprising one or more prefabricated drywall elements; at
least one skim coat deposited on the one or more prefabricated
drywall elements from a coating formulation comprising water, a
binder, a mineral filler and a noncellulosic thickener; and at
least one jointing material for assembling the one or more
prefabricated drywall elements by jointing the drywall elements to
form a substantially plane outer surface, the jointing material
comprising substantially the same solids as the coating
formulation, wherein the amount of water in the jointing material
is from about 10% to about 60% less than the amount of water in the
coating formulation.
[0008] In a further embodiment, a method for the construction of
interior walls is provided comprising assembling skim coated
prefabricated drywall elements, wherein the skim coated
prefabricated drywall elements have a coating layer of at least one
skim coat deposited on the prefabricated elements by a coating
device, the skim coat formed from a coating formulation comprising
water, a binder, a mineral filler, and a noncellulosic thickener;
jointing adjacent prefabricated elements with at least one jointing
material, the jointing material comprising substantially the same
solids as the coating formulation, wherein the amount of water in
the jointing material is from about 10% to about 60% less than the
amount of water in the coating formulation; and drying the jointing
material.
[0009] In a further embodiment, an interior construction system is
provided comprising one or more prefabricated drywall elements; at
least one skim coat deposited on the one or more prefabricated
drywall elements from a coating formulation comprising water, a
binder, a mineral filler and a noncellulosic thickener; and at
least one jointing material for assembling the one or more
prefabricated drywall elements by jointing the drywall elements to
form a substantially plane outer surface, the jointing material
comprising about 25 to about 45% water, about 40 to about 70% of a
mineral filler which is the same or different from the mineral
filler of the coating formulation, about 1.0 to about 3.0%
anti-cracking agent, about 1.0 to about 4.0% clay, about 0.1 to
about 1.0% thickener and water retention agent, about 1.0 to 5.0%
talc, about 0.5 to about 3.0% of a binder which is the same or
different from the binder of the coating formulation, and about 0.1
to about 1.0% starch.
[0010] In a further embodiment, a method for the construction of
interior walls is provided comprising assembling skim coated
prefabricated drywall elements, wherein the skim coated
prefabricated drywall elements have a coating layer of at least one
skim coat deposited on the prefabricated elements by a coating
device, the skim coat formed from a coating formulation comprising
water, a binder, a mineral filler, and a noncellulosic thickener;
jointing adjacent prefabricated elements with at least one jointing
material wherein the jointing material comprises about 25 to about
45% water, about 40 to about 70% of a mineral filler which is the
same or different from the mineral filler of the coating
formulation, about 1.0 to about 3.0% anti-cracking agent, about 1.0
to about 4.0% clay, about 0.1 to about 1.0% thickener and water
retention agent, about 1.0 to 5.0% talc, about 0.5 to about 3.0% of
a binder which is the same or different from the binder of the
coating formulation, and about 0.1 to about 1.0% starch; and drying
the jointing material.
[0011] An interior construction system is provided comprising one
or more prefabricated drywall elements; at least one skim coat
deposited on the one or more prefabricated drywall elements from a
coating formulation comprising water, a binder, a mineral filler
and a noncellulosic thickener; and at least one jointing material
for assembling the one or more prefabricated drywall elements by
jointing the drywall elements to form a substantially plane outer
surface, wherein the jointing material comprises 50 to 85% of a
mineral filler which is the same or different from the mineral
filler of the coating formulation; 1 to 20% of an organic binder
dispersible in an aqueous phase; 1 to 15% of a silicate-based
agent; 0.2 to 5% of a hydrophobic agent which is a silicone
derivative; 0.05 to 5% of polyvinyl alcohol; and water to make up
to 100%.
[0012] In a further embodiment, a method for the construction of
interior walls is provided comprising assembling skim coated
prefabricated drywall elements, wherein the skim coated
prefabricated drywall elements have a coating layer of at least one
skim coat deposited on the prefabricated elements by a coating
device, the skim coat formed from a coating formulation comprising
water, a binder, a mineral filler, and a noncellulosic thickener;
jointing adjacent prefabricated elements with at least one jointing
material wherein the jointing material comprises 50 to 85% of a
mineral filler which is the same or different from the mineral
filler of the coating formulation; 1 to 20% of an organic binder
dispersible in an aqueous phase; 1 to 15% of a silicate-based
agent; 0.2 to 5% of a hydrophobic agent which is a silicone
derivative; 0.05 to 5% of polyvinyl alcohol; and water to make up
to 100%; and drying the jointing material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The coating and jointing material systems provided afford
improved drywall installation efficiency and improvements in
texture, absorption characteristics, sanding characteristics,
processing characteristics and final performance characteristics.
The coated drywall products produced using the coating
formulations, jointing material and methods disclosed preferably
provide a final surface for the drywall that in some embodiments
substantially equals a level 5 skim-coated finish. The drywall
finish levels as used herein refer to the Levels of Gypsum Board
Finish of GA 214-96: Recommended Levels of Gypsum Board Finish
published in 1996. A level 5 finish is typically recommended for
areas where severe lighting conditions exist and areas that are to
receive gloss, semi-gloss, enamel or non-textured flat paints.
[0014] As used herein, the term "drywall" means any wall structure
especially for interior application, wherein the wall structure may
be prefabricated or not prefabricated material and includes gypsum
fiberboards, cement fiberboards, cement wallboards, plasterboards
and the like. Drywall elements typically are made of a gypsum or
plaster core sandwiched or faced in paper or cardboard and produced
like sheets which may be fastened to wall frames such as with nails
or screws. The drywall has a surface usually placed outwardly in an
interior construction such that there is a visible outer surface or
face ready to be decorated.
[0015] Conventionally, one of the sheets of paper used for making
drywall elements has a dark color which can vary between a gray
color and a chestnut color, since it is composed of cellulose
fibers which have not undergone any particular purifying treatment.
Traditionally, this so-called grey paper is obtained from
unbleached chemical pulp and/or from mechanical pulp, and/or from
thermomechanical pulp and/or from semi-chemical pulp. By mechanical
pulp, it is usually meant a pulp obtained entirely by mechanical
means from various raw materials, essentially wood, which can be
provided by salvaged products originating from wood, such as old
cardboard boxes, trimmings of kraft paper and/or old newspapers.
Thermomechanical pulp means a pulp obtained by thermal treatment
followed by a mechanical treatment of the raw material. By
semi-chemical pulp is meant a pulp obtained by eliminating some of
the non-cellulose components from the raw material by means of
chemical treatment and requiring a subsequent mechanical treatment
in order to disperse the fibers.
[0016] The other sheet of a drywall element has a visible face,
called a lining face, which may be of a color generally lighter
than the gray sheet. To obtain this lighter color, the layer or
layers of this face are based on chemical pulp, if appropriately
bleached, composed of recycled and/or new cellulose fibers, and/or
on mechanical pulp, if appropriately bleached. By chemical pulp is
meant a pulp obtained by eliminating a very large proportion of the
non-cellulose components from the raw material by chemical
treatment, for example, by cooking in the presence of suitable
chemical agents, such as soda or bisulfites. When this chemical
treatment is completed by bleaching, a large part of the colored
substances is eliminated, as well as the substances which risk
decomposing by ageing and giving unpleasant yellow shades
associated with the presence of, for example, lignin. The coating
provided preferably is applied to this face of the drywall;
however, the coating may be applied to any type of paper or outer
surface utilized in the manufacture of drywall, including printed
paper and the like. The jointing material is applied upon
installation to finish the construction of the interior walls using
the coated drywall elements.
[0017] Generally, the coating is applied to all or a portion of the
surface of the drywall either during prefabrication of the drywall
elements or boards or after installation in the interior of a
structure. The coating has a composition compatible with the
jointing material and is applied as a skim coat or film coat of
relatively low thickness on the visible surface of the drywall. One
or more coats may be applied. The coating preferably provides a
substantially homogeneous appearance to the drywall even after the
joints are prepared as is known in the art. The characteristics of
the coating are such that the coating and jointing materials
utilized in the installation of drywall compatibly provide a
substantially homogeneous appearance. The drywall installation is
simplified since one or more layers of primer or paint or finishing
coats are not required to complete the preparation of the wall for
decoration. Specifically, in preferred embodiments, when the
coating is applied to drywall, an additional skim coat or finishing
coat is not required to obtain a level 5 finish.
[0018] The jointing materials described herein are used to complete
the construction of the interior surface of the interior structure
installed with coated drywall. The jointing material may be used
for any purpose for which such materials are known such as jointing
compounds, sealing coats, joint coats or joint-pointing coats.
[0019] After the coating and jointing material system has been
applied to drywall, the jointing material jointing the skim coated
drywall elements and the skim coated drywall elements form a
substantially plane outer surface comprising a surface of the
jointing material and a surface of the skim coated drywall
elements. This surface may then be decorated as is known in the art
by application of a paint or wallpaper covering.
[0020] The Coating Formulation
[0021] The coating provides a smoothing of the texture of the
drywall such that the fibers typically seen under primer or paint
after installation of the drywall are substantially covered.
Moreover, the coating changes the characteristics of the drywall to
provide a surface with an absorbance closer to the absorbance of
the jointing material surface when dry, which surface is thus
visually substantially uniform. The coating also provides a durable
surface such that the sanding on the jointing material does not
easily remove or damage the coating surface. Thus, the coating
preferably provides a durable surface with a sufficiently smooth
texture and absorbance to be substantially compatible with the
jointing material.
[0022] The coating typically is a drying type coating and the
coating formulation comprises water, mineral filler, binder and
thickener. The coating preferably also includes a dispersant. The
coating is described in detail herein and also in the copending
application entitled "Coating for Wall Construction", filed on even
date herewith and coassigned with the present application,
incorporated by reference herein in its entirety.
[0023] The water is provided in an amount effective to provide a
suitable viscosity to the coating formulation such that the coating
formulation may be applied by any desirable means to the drywall
material.
[0024] The mineral filler may be any of the fillers known in the
art for use in surface coating compositions or a combination
thereof. Preferably, the mineral filler is of light color,
preferably white with a grain size or particle size distribution
wherein the mean diameter D50 is between about 5 and about 35
.mu.m, as determined by light scattering techniques. Too large a
grain size of the filler gives rise to overall surface defects,
such as a reflection of light radiation on the surface of the coat
which is different from that on the surface of the drywall,
bringing about differences in tone and brightness of the shade. Too
large a grain size also gives rise to differences in physical
appearance which are associated with the differences in roughness
between the board and the coating.
[0025] Preferably, the mineral filler comprises more than about 60%
calcium carbonate, more preferably more than about 75%, and most
preferably greater than about 90% calcium carbonate. Other fillers
may also be used in lesser amounts, such as magnesium carbonate,
dolomite, gypsum, anhydrite and the like. By way of example,
calcium carbonate filler such as Pulpro 15 from OMYA may be used.
The mineral filler represents about 40 to about 70% of the total
weight of the coating formulation. Preferably, the mineral filler
represents about 45 to about 65% of the total weight of the coating
formulation.
[0026] The coating formulation preferably further comprises a
dispersant. The dispersant provides cohesion for the formulation,
holding the components of the formulation in suspension even where
the viscosity of the coating formulation is relatively low for a
coating material. The dispersant may include any dispersant or
mixtures thereof which function as desired, preferably any
polyacrylate or polymeric acrylic salt or mixtures thereof, more
preferably a salt of polyacrylate such as a sodium polyacrylate. By
way of example, Acumer.RTM. 9300 or Acumer.RTM. 9400 produced by
Rohm and Haas Company may be used.
[0027] The dispersant preferably represents about 0.5 to about
15.0% of the total weight of the coating formulation. More
preferably, the dispersant represents about 1.0 to about 5.0% of
the total weight of the coating formulation.
[0028] The coating formulation also comprises an organic binder
dispersible in aqueous phase, in a proportion of between about 0.5
and about 15.0%, and preferably between about 1.0 and about 4.0%,
of the total weight of the coating formulation. The binder
preferably imparts sufficient flexibility to the coat to withstand
mechanical stresses, and has both an adhesive capacity for
obtaining a good bond on the overall surface and good resistance to
attacks of ultraviolet light. In addition, the binder typically
will function to harden the surface of the coating after
application.
[0029] The binder in the coating formulation preferably will be a
latex binder, or a mixture of such binders. In a preferred
embodiment, the binder is an acrylic latex binder. By way of
example, an acrylic latex such as AC-630 from Rohm and Haas Company
may be used.
[0030] The coating formulation further comprises a thickening agent
which provides an increase in viscosity and functions to aid in
holding the components of the coating formulation in suspension.
The thickening agent preferably is primarily a noncellulosic
thickener or a mixture of noncellulosic thickeners. In some
embodiments, other thickeners known in the art such as cellulosic
thickeners may be included in the formulation as part of a mixture
of thickening agents.
[0031] By way of example, noncellulosic thickeners generally
identified as alkali soluble emulsions or hydrophobically modified
alkali soluble emulsions may be used. More preferably, the
thickener is a polymeric noncellulosic thickener such as a
polyacrylate, especially a copolymer of an acrylic acid and an
acrylic ester. In a most preferred embodiment, the thickener is a
copolymer of acrylate and methacrylic acid. By way of example,
ASE-60, a polyacrylate of the alkali soluble emulsion category, or
TT-615, a polyacrylate of the hydrophobically modified alkali
soluble emulsion category, both from Rohm and Haas Company, may be
used.
[0032] The thickener generally is used in a proportion of about
0.05 to about 50%, and preferably of about 0.1 to about 5.0%, of
the total weight of the coating formulation.
[0033] In addition to the water, mineral filler, dispersant, binder
and thickener, at least one workability agent may be included in
the composition of the coating formulation, especially a clay, in
the proportion of about 0.1 to about 5.0%, and preferably of about
1.0 to about 2.0%, of the total weight of the coating formulation.
The workability agent is preferably one or more silicate
derivatives and, more preferably, a clay of the attapulgite type,
such as M8214 from Engelhard.
[0034] An anti-cracking material may also be desirable in the
coating formulations. Such materials are known in the art and may
include materials such as mica. By way of example, MW 200 from
Oglebay Norton may be used. The anti-cracking agent may represent
about 0.1 to about 20% of the total weight of the coating
formulation. Preferably, the anti-cracking agent will represent
about 1.0 to about 2.0% of the total weight of the coating
formulation.
[0035] Other components, such as biocides, anti-foaming agents,
preservatives, water treatment agents and pigments may also be
incorporated in the composition of the coating formulation in the
conventional way. For example, a water treatment agent may be
needed to adjust the pH of the coating formulation depending on the
water used or the ultimate use of the formulation. Such water
treatment agent may be bicarbonate, which may be used in certain
embodiments to ensure the pH is above about 8. Preservatives are
known in the art and include such materials as
hexahydro-1,3,5-tris(2-hydroxyethyl)-s-triazine. By way of example,
Troysan 165 from Troy Corporation may be used. The additional
components such as biocides, anti-foaming agents, preservatives,
water treatment agents and pigments are typically used in
relatively minor amounts, generally less than about 1.0% of the of
the total weight of the coating formulation.
[0036] The coating formulation, by way of example, may be prepared
by combining a first fraction of water with the binder and
dispersant and mixing the combination. If a water treatment agent
such as bicarbonate is to be added, such agent may be included in
the first mixing step. The viscosity of the formulation should be
kept as high as possible for as long as possible in order to
effectively optimize the mixing process.
[0037] After sufficiently mixing the binder and dispersant with the
first fraction of water, the mineral filler such as calcium
carbonate is added, followed by the mica and the clay. If a
preservative is to be used, the preservative may be added in this
step, along with other optional components known to those of skill
in the art. The coating formulation is further mixed prior to
addition of the thickener. The remaining water preferably is added
last; however, if the coating formulation mixture after addition of
the mineral filler has a high viscosity, e.g., the coating
formulation mixture is too thick, some water may be added prior to
adding the thickener. Any water remaining may be added after
addition of the thickener.
[0038] Typically, the viscosity of the coating formulation will be
about 250 to about 1200 cps, more preferably about 300 to about 450
cps, as determined by a Brookfield viscometer at room temperature.
By way of example, the viscosity may be measured for the coating
formulation using T-bar spindle number S91 with 100 rpm. The
viscosity of a jointing material may be measured, for example,
using T-bar spindle number S94 with 2.5 rpm. The viscosity may be
adjusted by any means known in the art to provide a coating
formulation suitable for the desired application.
[0039] The coating formulation preferably is used on prefabricated
drywall elements, preferably flat prefabricated elements such as
gypsum fiberboards, cement fiberboards, gypsum wallboards, plaster
boards and the like.
[0040] The coating formulation preferably is applied as a skim
coat, or film coat of relatively low thickness on the outer surface
of drywall made from prefabricated elements. The coat may be
applied before or after the drywall is sent through a drier.
Preferably, however, the coat will be applied prior to the drier so
that the coat may be dried as the core is dried.
[0041] The skim coat may be applied, by way of example, in the
plant by, for instance, roll coating, curtain coating, vacuum
coating, spraying or the like via a coating device, on the
prefabricated element so that the skim-coated prefabricated element
is delivered to the assembly site already with a skim coat on it.
Alternatively, the coating formulation may be supplied to the user
for application to the drywall or boards after the drywall or
boards are placed into position during interior construction. The
skim coat from the coating formulation provides a substantially
uniform surface with the joint compound used to install the drywall
or boards upon which the skim coat is placed.
[0042] The coating formulation preferably is applied using a
spraying device, which is operated under standard conditions for
coating a product onto a board. The dimensions, rotating speed,
feeding, temperature, and any other operating conditions are within
the skill of a person of ordinary skill in the art. In a preferred
embodiment, the coating is applied by a system as disclosed in the
copending application entitled "Coating Spray Apparatus and Method
of Using Same", filed on even date herewith and coassigned with the
present application, incorporated by reference herein in its
entirety.
[0043] By way of example, drywall material such as gypsum board is
prepared according to standard practices, including depositing a
calcined gypsum slurry between two sheets. Methods of producing
gypsum board, including coated gypsum board, are described for
example in copending, coassigned U.S. patent application Ser. No.
10/625,624, filed Jul. 24, 2003, incorporated herein by reference
in its entirety. The coating formulation may be applied after the
gypsum sets but prior to the gypsum being completely dry.
Thereafter, the gypsum wallboard is dried in conventional driers
which dries both the coating and the gypsum. It has been discovered
that the coating is sufficiently permeable to allow moisture in the
gypsum to be satisfactorily eliminated through the paper and the
coating thereon. An impermeable substance applied to the paper
cover sheet of the gypsum wallboard when the core is still wet may
cause the paper sheet to separate or delaminate from the core as
moisture is driven off in the drier. The coating formulation
provided, however, may be advantageously applied during manufacture
of the drywall without substantially negatively affecting the
drying characteristics of the core material or time required for
drying the core material.
[0044] The final thickness of the coat from the coating
formulation, as determined when dry, is generally between about 5
and about 60 mil, preferably between about 10 and about 15 mil.
[0045] The selection of the jointing material used with the coating
may be made such that the jointing material, when dry,
substantially matches the coating on the drywall element or board.
Since the composition of the jointing material and the coat are
adapted to match each other, the jointing material and the coat
form, both in a dry state, a substantially homogeneous outer
surface having over substantially all its surface at least one of
the parameters comprised in the group consisting of coloration,
reflectance factor and surface water absorption which is
substantially homogeneous over the surface. For instance, the at
least one of the parameters differs by no more than 10%, preferably
no more than 5%, at different parts of the overall surface, so that
at least 90%, preferably at least 95%, homogeneity is achieved. In
other words, as an example, when the jointing material and the
prefabricated elements are dry, the at least one of the parameters
of the visible surface of the jointing material can differ by not
more than 10%, preferably not more than 5%, from the corresponding
parameter of the visible surface of the prefabricated elements.
[0046] The characteristics of the surfaces may be compared by the
following tests: (A) Color. The color deviations delta E* are
measured on a spectro-colorimeter according to the standard DIN
6174 at an angle of 8.degree., illuminant D65 as a bright specular,
included in the system L*, a*, b*, in which L* is the luminance, a*
represents the transition from green to red, and b* represents the
transition from blue to yellow. A point E* in this system, the said
point being a function of L*, a*, b*, defines the colorimetry of a
sample and the deviation is measured in relation to a reference
point. In general terms, a color deviation beyond 2 becomes
discernible to the naked eye. (B) Degree of whiteness or
reflectance factor R obtained according to standard NFQ 03038 with
a wavelength of 457 nm. This degree represents the a reflected
radiation of the body in question and that of a perfect diffuser
under the same conditions. Preferably the whiteness is between 70
and 80%, most preferably between 72 and 76%. (C) Surface water
absorption determined by the drop test. A drop of distilled water
of a volume of approximately 0.05 cm.sup.3 at 23.degree. C. is
deposited on the surface (conditioned atmosphere). It is important
that the drop be deposited and not allowed to fall from a variable
height which consequently would crush it to a greater or lesser
extent, thus falsifying the result. The duration in minutes (time
for the glossy surface to disappear) represents the surface
absorption of the tested area.
[0047] According to a preferred embodiment, the jointing material
and the coating exhibit substantially the same surface water
absorption or absorbability. In one embodiment, the surface water
absorption, as measured by the drop test, is at least 45 minutes
for both the joint and the board, preferably at least 60 minutes.
Preferably, the jointing material and the coating exhibit also
substantially the same coloration and/or reflectance factor.
[0048] A suitable jointing material may be selected according to
the preceding description and/or may be selected from the
embodiments of jointing material set forth below.
Jointing Material--Preferred Embodiment No. 1
[0049] In one embodiment, the jointing material preferably used
with the coating described is derived from the components of the
coating formulation. Thus, the jointing material in this embodiment
comprises water, mineral filler, binder, thickener, and optionally,
dispersant. This jointing material provides a substantially similar
surface as the coating as to texture and absorbance, enabling the
coating and jointing material when dry to preferably provide a
level 5 finish without application of a skim or final coat. Thus, a
final skim coat may be eliminated from the preparation of the wall,
saving time and money when constructing interior walls.
[0050] The jointing material of this embodiment preferably is
formulated to comprise substantially the same components as the
coating formulation, with variations in the amounts of each
component according to the desired characteristics. Since the
jointing material and the coating formulation comprise
substantially the same components, the properties of the coating
and jointing material are compatible and preferably provide the
desired substantially homogeneous surface for the drywall
construction.
[0051] Preferably, the jointing material of this embodiment will
comprise about 40 to about 70% mineral filler, wherein the mineral
filler is greater than about 60% calcium carbonate, about 0.5 to
about 15.0% binder, about 0.05 to about 50% noncellulosic
thickener, optionally about 0.5 to about 15.0% dispersant, about
0.1 to about 5.0% workability agent and about 0.1 to about 20%
anti-cracking agent, all by weight. Other components may also be
present in minor amounts as discussed for the coating formulation.
Water is provided in an amount to make up 100% of the jointing
material.
[0052] Water is present in the jointing material in an amount
effective to provide a suitable viscosity to the jointing material
such that the jointing material may be applied by any desirable
means to effect assembly of the drywall elements. Since the
jointing material typically has a higher viscosity than a coating
composition, the jointing material will preferably include less
water than the coating formulation. The coating formulation may, in
a preferred embodiment, be a diluted version of the jointing
material. For example, compared to the jointing material such as
the joint-pointing coat, the coating, when applied (for example,
when the coating is applied to the prefabricated elements, or when
the skim coated prefabricated elements are assembled), will
comprise more water than initially present in the jointing
material. It will thus generally comprise additional water, e.g.,
about 10 to 60%, preferably about 15 to 40%, more preferably about
25%, more water than initially present in the jointing material. By
"water initially present in the jointing material", it means the
amount of water present in the jointing material when the jointing
material is applied to the skim coated prefabricated elements,
before the jointing material is in a dry state.
[0053] In a most preferred embodiment, the jointing material and
the coating formulation preferably have substantially the same
solids formulation, the coat when applied having a solids content
lower than the jointing material when applied. Thus, in this
preferred embodiment, substantially the same filler, binder,
thickener and other optional components of the coating formulation
are present in the jointing material.
Jointing Material--Preferred Embodiment No. 2
[0054] In another embodiment, a jointing material comprising water,
mineral filler, binder, thickeners and rheologic agents, and an
anti-cracking agent is provided.
[0055] The filler may be any of the fillers known for jointing
materials such as such as calcium carbonate, magnesium carbonate,
dolomite, gypsum, anhydrite and the like, including combinations
thereof. Preferably, the filler will comprise at least about 60%
calcium carbonate. The filler, by way of example, may by Pulpro
15.
[0056] The binder may be an acrylic polymer typically used as a
binder. One example of a suitable binder is AC630 from Rohm and
Haas Company.
[0057] The thickeners and rheologic agents may be selected from one
or more silicate compounds or from starches. Particularly, one or
more clays, such as attapulgite, may be used. By way of example,
Engelhard M8214 or Attagel 30 may be used. Another silicate, talc,
may also preferably be used as a rheologic agent, preferably in
conjunction with one or more clay components. For example, Luzenac
TC100 may be used. Starch may also preferably be used as an
additional thickener and rheologic agent. As an example, Starpol
136, 767 or 600, amylopectin hydrogen phosphate 2-hydroxypropyl
ether, may be used. In a most preferred embodiment, the jointing
material includes each of a clay, talc and a starch as rheologic
and thickening agents.
[0058] Preferably, a thickener and water retention agent is also
used, such as a cellulose compound or mixture of cellulose
compounds. Suitable cellulose compounds include hydroxypropyl
methylcellulose compounds such as Dow Chemical Methocel 240S,
Methocel 40320 or Samsung PMC40US.
[0059] The anti-cracking agent may be any agent known for this
purpose. Preferably, the anti-cracking agent is mica such as
Georgia Mineral SG75 or Oglebay Norton MW200.
[0060] Preferably, the jointing material comprises:
[0061] water--about 25 to about 45%
[0062] filler--about 40 to about 70%
[0063] anti-cracking agent--about 1.0 to about 3.0%
[0064] clay--about 1.0 to about 4.0%
[0065] thickener and water retention agent--about 0.1 to about
1.0%
[0066] talc--about 1.0 to 5.0%
[0067] binder--about 0.5 to about 3.0%
[0068] starch--about 0.1 to about 1.0
Jointing Material--Preferred Embodiment No. 3
[0069] In another embodiment, the jointing material described in
U.S. Patent Application Publication No. 2003/0153651, incorporated
herein by reference in its entirety, may be employed as the
jointing material.
[0070] The jointing material or plaster described in the '651
publication is directed to a composition of
[0071] 50 to 85% of a mineral filler;
[0072] 1 to 20% of an organic binder dispersible in an aqueous
phase;
[0073] 1 to 15% of a silicate-based agent;
[0074] 0.2 to 5% of a hydrophobic agent which is a silicone
derivative;
[0075] 0.05 to 5% of polyvinyl alcohol; and
[0076] water to make up to 100%.
[0077] As mineral filler, any mineral filler commonly employed for
the manufacture of a jointing compound or plaster may be used. In
general, the mineral filler will be light in colour, preferably
white, and the mean diameter d.sub.50 of which is in general
between 5 and 35 microns as determined by light scattering
techniques, so that the jointing material after drying gives a
smooth finish corresponding to that of the facing of the board.
[0078] As examples of mineral filler, mention may be made of
calcium carbonate, anhydrous or dihydrated calcium sulphate,
magnesium carbonate, dolomite, silicas, silicates, aluminates and
other such materials.
[0079] Preferably, calcium carbonate CaCO.sub.3 is used.
[0080] The mineral filler preferably represents between 50 and 70%
of the total weight of the jointing material.
[0081] According to one embodiment, the binder/silicate-based agent
weight ratio is between 0.5 and 2.
[0082] According to one embodiment, the binder/hydrophobic agent
weight ratio is between 1.5 and 10.
[0083] According to an advantageous embodiment, the mineral filler
furthermore includes perlite, preferably expanded and even more
preferably hydrophobic perlite. The amount of perlite is then
generally between 2 and 5%.
[0084] As organic binder dispersible in an aqueous phase, mention
may be made of polyvinyl acetate homopolymers (plasticized or
unplasticized), ethylene/vinyl acetate copolymers (plasticized or
unplasticized EVAs), ethylene/vinyl versatate copolymers, vinyl
acetate/vinyl versatate copolymers, polyacrylics, vinyl
acetate/acrylic copolymers, styrene/acrylic copolymers,
styrene/butadiene copolymers, vinyl acetate/vinyl versatate/vinyl
maleate terpolymers, vinyl acetate/vinyl versatate/acrylic
terpolymers, acrylic terpolymers and blends thereof.
[0085] The proportion of organic binder is preferably between 2 and
12% of the total weight of the jointing material.
[0086] The silicate-based agent (different from the mineral filler)
preferably comprises talc and/or mica and/or a clay. Preferably, a
mixture of talc and mica is used.
[0087] The proportion of silicate-based agent is preferably between
3 and 10% of the total weight of the jointing material.
[0088] The hydrophobic agent is a silicone derivative. As silicone
derivatives, mention may be made of siliconates, silanes,
hydrogenated silicone oils, silicone emulsions, aminosilicone
emulsions, alkylsiloxane resins, such as
hydrogenomethyl-polysiloxane and aminated polydimethyl-siloxane,
and mixtures thereof.
[0089] Preferably, a resin of the aminated polydimethyl-siloxane
type is used as silicone derivative.
[0090] The proportion of silicone derivative is preferably between
0.5 and 3% of the total weight of the jointing material.
[0091] Advantageously, the proportion of silicone derivative is
chosen so as to allow a joint to be produced which has the same
surface properties as those of the facing paper. These surface
properties are decolouration or colouration owing to the effect of
the natural color, reflectance and surface water absorption. These
properties are described above.
[0092] The proportion of polyvinyl alcohol is preferably between
0.05 and 1% of the total weight of the jointing material.
[0093] According to an advantageous embodiment, the jointing
material furthermore includes starch and/or a starch
derivative.
[0094] The proportion of starch and/or starch derivative is in
general between 0.05 and 5%, preferably between 0.1 and 1%, of the
total weight of the jointing material.
[0095] The jointing material may be prepared by mixing its
constituents in any order.
[0096] Of course, provided that the proportions assigned to each of
the essential constituents are respected, it is possible to
introduce into the jointing material according to the invention, as
secondary ingredients, additives normally used to facilitate the
processing of the other constituents or for conferring additional
particular properties on the jointing material. By way of examples
of such additives, mention may be made of water-retaining agents or
thickeners, slip agents, dispersants, antigels, pigments, biocides
and antifoams. These additives are described, for example, in the
application WO-A-9702395, incorporated herein by reference.
[0097] Embodiments of the invention will now be more fully
explained by the following examples. However, the scope of the
invention is not intended to be limited to these examples.
EXAMPLE 1
[0098] A coating formulation according to an embodiment as set
forth in Table 1 was prepared as follows:
[0099] To the first part of the water, bicarbonate, binder, and
dispersant were added and mixed. The calcium carbonate was then
added and mixed, followed by the mica, clay and preservative, which
were also mixed. The thickener then was added and mixed into the
formulation. The remaining water was added after the thickener was
mixed into the formulation.
1TABLE 1 Material Name Pounds Dry Solids % Water 294.68 21.8
Bicarbonate 0.42 100 0.03 AC-630 resin, binder (acrylic latex)
25.79 50 1.91 Acumer 9400, dispersant (sodium 27.09 42.5 2.00
polyacrylate) Calcium carbonate 771.28 100 57.06 Mica 26.43 100
1.96 Clay 19.32 100 1.43 ASE-60, thickener (copolymer acrylate and
1.62 28 0.12 methacrylic acid) Water 185.00 13.6 Total Pounds
1351.63 Weight solids (%) 61.40 % Dispersant - total formulation
2.00 % thickener - total formulation 0.12 % binder - total
formulation 1.91
EXAMPLE 2
[0100] A coating formulation according to Table 2 was prepared
according to the procedures of Example 1.
2TABLE 2 Material Name Pounds Dry Solids % Water 297.56 21.80
Bicarbonate 0.43 100 0.03 AC-630 resin, binder (acrylic latex)
26.25 50 1.92 Acumer 9300, dispersant (sodium 27.38 45 2.00
polyacrylate) Calcium carbonate 784.89 100 57.51 Mica 26.90 100
1.97 Clay 19.66 100 1.44 TT-615, thickener (copolymer acrylate and
1.64 30 0.12 methacrylic acid) Water 180.00 13.19 Total Pounds
1364.71 Weight solids (%) 61.90 % Dispersant - total formulation
2.00 % thickener - total formulation 0.12 % binder - total
formulation 1.92
EXAMPLE 3
[0101] A jointing material according to preferred embodiment no. 2
was prepared with the following composition:
[0102] water--33.0%
[0103] limestone (CaCO.sub.3)--57.0%
[0104] mica--2.0%
[0105] clay attapulgite--2.5%
[0106] hydroxypropyl methylcellulose--0.5%
[0107] talc--3.0%
[0108] acrylic polymer--1.5%
[0109] starch--0.5%
[0110] While the preferred embodiments of the invention have been
disclosed in detail, it will be apparent to one skilled in the art
that various changes and modifications can be made without
departing from the spirit and scope thereof.
* * * * *