Dry mortar formulations modified with water-redispersible polymer powders

• US 20030005861A1
• Filed: 05/14/2002
• Published: 01/09/2003
• Est. Priority Date: 05/17/2001
• Status: Active Grant

• Current Assignee: Wacker Chemie AG (Dr. Alexander Wacker Familiengesellschaft Mit Beschrã¤Nkter Haftung)
• Original Assignee: Wacker Polymer Systems GmbH & Co. KG
• Inventors: Dietrich, Ulf, Mayer, Theo
• Granted Patent: US 6,709,508 B2
• Time in Patent Office: Days
• US Class Current: 106/727
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0608 Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use

Abstract

Dry mortar formulations comprising

a) from 0.5 to 80% by weight of hydraulic binder,

b) from 0 to 97% by weight of fillers,

c) from 0 to 3.5% by weight of thickeners,

d) from 1.0 to 80% by weight of redispersible polymer powder, and

e) from 0.0001 to 1.0% by weight of antioxidants

exhibit improved tensile strength and other set mortar properties, particularly after storage of the dry mortar composition.

Claims

1. A dry mortar formulation comprising

a) from 0.5 to 80% by weight of a hydraulic binder,

b) from 0 to 97% by weight of a filler,

c) from 0 to 3.5% by weight of a thickener,

d) from 1.0 to 80% by weight of a redispersible polymer powder, and

e) from 0.0001 to 1.0% by weight of an antioxidant the percentages by weight based on the overall weight of the dry mortar, and totaling 100% by weight.

2. The mortar of claim 1, comprising as redispersible polymer powders d) a redispersible polymer powder based on one or more unbranched C_1-15 alkylcarboxylic acid vinyl ester monomers, branched C_1-15 alkylcarboxylic acid vinyl ester monomers, C_1-10 alcohol (meth)acrylic acid ester monomers, vinylaromatic monomers, olefin monomers, diene monomers, or vinyl halide monomers.

3. The mortar of claim 1, comprising as antioxidants e) one or more sterically hindered phenol antioxidants, sterically hindered hydroquinone antioxidants, aromatic amine antioxidants, organosulfur compound antioxidants, phosphite antioxidants, or phosphonite antioxidants.

5. The dry mortar of claim 1 wherein said hydraulic binder comprises gypsum.

6. A process for preparing the mortar of claim 1, comprising mixing components a) to e) in a powder mixer.

7. A process for preparing the mortar of claim 1, wherein the antioxidant e) is added to a redispersible polymer powder d) or added during spray drying when preparing the redispersible powder d), and subsequently mixing the antioxidant-containing polymer powder with the other components of the dry mortar.

8. A process for preparing a mortar compound using a mortar composition of claim 1, comprising adding individual components a) to e) to water and agitating to form a mortar compound.

9. In a process for adhesively loading or coating a substrate wherein a mortar compound is employed, the improvement comprising admixing the dry mortar of claim 1 with water to form a mortar compound, and applying said mortar compound to said substrate.

10. The process of claim 9, wherein said substrate is a tile.

11. The process of claim 9, wherein said substrate comprises an insulation panel or a soundproofing panel.

12. The process of claim 9, wherein said mortar compound is a reinforcing compound for exterior insulation and finish systems.

13. The process of claim 9, wherein said mortar compound is a troweling compound.

14. The process of claim 9, wherein said mortar compound is a grout.

15. An adhesive, render, reinforcing compound, troweling compound, or grout comprising the dry mortar of claim 1 and water.

16. A gypsum plaster or gypsum troweling compound comprising the dry mortar of claim 5 and water.

4. A dry mortar formulation comprising

a) from 8 to 50% by weight of cement,

b) from 40 to 90% by weight of calcium carbonate and/or quartz sand fillers,

c) from 0.05 to 0.8% by weight of one or more cellulose ether thickeners, modified cellulose ether thickeners, polyvinyl alcohol thickeners, or acetalized and/or hydrophobically modified polyvinyl alcohol thickeners,

d) from 1 to 10% by weight of polyvinyl-alcohol-stabilized redispersible polymer powder, said polymer powder based on one or more unbranched C_1-15 alkylcarboxylic acid vinyl ester monomers, branched C_1-15 alkylcarboxylic acid vinyl ester monomers, C_1-10 alcohol (meth)acrylic acid ester monomers, vinylaromatic monomers, olefin monomers, diene monomers, or vinyl halide monomers, and

e) from 0.001 to 0.1% by weight of one or more sterically hindered phenol antioxidants, sterically hindered hydroquinone antioxidants, aromatic amine antioxidants, organosulfur compound antioxidants, phosphite antioxidants, or phosphonite antioxidants.