PLASTISOL COMPOSITIONS INCLUDING ORGANOSILICON COMPOUND(S)

• US 20140087612A1
• Filed: 09/24/2012
• Published: 03/27/2014
• Est. Priority Date: 09/24/2012
• Status: Active Grant

• Current Assignee: Chomarat North America LLC (Chomarat)
• Original Assignee: Chomarat North America LLC (Chomarat)
• Inventors: Hart, George, Grindle, Ronny
• Granted Patent: US 10,329,439 B2
• Time in Patent Office: Days
• US Class Current: 442/1
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: C03C 25/103 Organic coatings
• CPC Class Codes: C03C 25/28 obtained by reactions involving only carbon-to-carbon unsaturated bonds
• CPC Class Codes: C03C 25/40 Organo-silicon compounds
• CPC Class Codes: C03C 25/50 Coatings containing organic materials only
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 20/1029 Macromolecular compounds
• CPC Class Codes: C04B 20/1051 Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 20/12 Multiple coating or impregnating
• CPC Class Codes: C04B 2103/12 Set accelerators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 22/143 : Calcium-sulfate
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 7/32 : Aluminous cements
• CPC Class Codes: C09D 7/63 : organic
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/2962 : Silane, silicone or siloxane in coating
• CPC Class Codes: Y10T 428/2967 : Synthetic resin or polymer
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

Plastisol compositions are provided including a polymeric resin in the form of particulates dispersed within a plasticizer and one or more hydrolyzable organosilicon compounds. A suitable solvent system can be utilized in the plastisol compositions. Also provided are inorganic fibers, and particularly reinforcing scrims, that are at least partially coated with a plastisol composition including one or more hydrolyzable organosilicon compounds. Cementitious boards reinforced with plastisol coated inorganic fibers, such as mesh scrims, are also provided.

Claims

1. A plastisol composition, comprising:

(i) a plasticizer;

(ii) a polymeric resin provided in the form of particulates and dispersed within said plasticizer; and

(iii) one or more hydrolyzable organosilicon compounds (“

HOC”

).

2. The composition according to claim 1, wherein the one or more HOC comprises an organo-functional silane, organo-functional siloxane, organo-functional polysiloxane, or combinations thereof.

3. The composition according to claim 2, wherein the one or more HOC comprises amine functionality.

4. The composition according to claim 2, wherein the one or more HOC comprises epoxide functionality.

5. The composition according to claim 2, wherein the one or more HOC comprises at least one functionality selected from the group consisting of amine, epoxide, vinyl, acrylate, ester, ether, acyl halide, carboxylic acid, peroxide, carbonyl, cyanate, and nitrile.

6. The composition according to claim 3, wherein the one or more HOC includes an amine functional polysiloxane.

7. The composition according to claim 6, wherein the one or more HOC comprises a cross-linkable amine functional dialkylpolysiloxane.

8. The composition according to claim 4, wherein the one or more HOC comprises a residue of glycidol.

9. The composition according to claim 8, wherein the one or more HOC comprises 3-glycidyloxypropyltrimethoxysilane.

10. The composition according to claim 1, wherein the one or more HOC includes at least one alkoxy group bonded to a Si atom.

11. The composition according to claim 1, wherein the one or more HOC comprises an alkoxy aminofunctional dialkylpolysiloxane selected from the following:

12. The composition according to claim 1, wherein the polymeric resin comprises polyvinyl chloride (“

PVC”

).

13. The composition according to claim 1, wherein the composition comprises from 0.01 to 20.0 parts per hundred resin (“

phr”

) of said one or more HOC.

14. The composition according to claim 13, wherein the composition comprises from 0.25 to 5.0 phr of said one or more HOC.

15. The composition according to claim 1, further comprising a stabilizer, a solvent system, or combination thereof.

16. The composition according to claim 1, further comprising one or more additives selected from inorganic fillers, pigments, blowing agents, and antimicrobials.

17. A coated fiber, comprising:

an inorganic fiber indirectly or directly at least partially coated with a plastisol composition, said plastisol composition comprising (i) a plasticizer;

(ii) a polymeric resin; and

(iii) one or more hydrolyzable organosilicon compounds (“

HOC”

).

18. The fiber according to claim 17, wherein the inorganic fiber is substantially completely coated with the plastisol composition.

19. The fiber according to claim 17, wherein the plastisol composition is directly coated onto the inorganic fiber such that that plastisol composition is directly adjacent the inorganic fiber.

20. The fiber according to claim 17, further comprising a sizing composition positioned directly adjacent the inorganic fiber and sandwiched between the inorganic fiber and the plastisol composition.

21. The fiber according to claim 20, wherein the sizing composition includes one or more silanes, organosilanes, or polysiloxanes.

22. The fiber according to claim 20, wherein the sizing composition is devoid of one or more silanes, organosilanes, or polysiloxanes.

23. The fiber according to claim 17, wherein the inorganic fiber is a single strand.

24. The fiber according to claim 17, wherein the inorganic fiber comprises a yarn of multiple inorganic filaments.

25. The fiber according to claim 24, wherein the inorganic filaments comprise fiberglass.

26. The fiber according to claim 17, wherein the inorganic fiber comprises fiberglass.

27. A scrim, comprising:

a mesh of inorganic fibers defining a plurality of cross-points and a plurality of open spaces, said inorganic fibers comprising a solidified plastisol coating layer comprising a plastisol composition comprising (i) a plasticizer;

(ii) a polymeric resin; and

(iii) one or more hydrolyzable organosilicon compounds (“

HOC”

), said coating layer being indirectly or directly at least partially coated onto the inorganic fibers.

28. The scrim according to claim 27, wherein the inorganic fibers are substantially completely coated with the plastisol coating layer.

29. The scrim according to claim 27, wherein the plastisol coating layer is positioned directly onto the inorganic fibers such that that plastisol coating layer is directly adjacent the inorganic fibers.

30. The scrim according to claim 27, wherein the inorganic fibers further comprise a sizing composition positioned directly adjacent the inorganic fibers and sandwiched between the inorganic fibers and the plastisol coating layer.

31. The scrim according to claim 30, wherein the sizing composition includes one or more silanes, organosilanes, or polysiloxanes.

32. The scrim according to claim 30, wherein the sizing composition is devoid of one or more silanes, organosilanes, or polysiloxanes.

33. The scrim according to claim 27, wherein the inorganic fibers comprise individual single strands.

34. The scrim according to claim 27, wherein the inorganic fibers comprise yarn of multiple inorganic filaments.

35. The scrim according to claim 34, wherein the inorganic filaments comprise fiberglass.

36. The scrim according to claim 27, wherein the inorganic fibers comprises fiberglass.

37. A reinforced cementitious board, comprising:

(i) a matrix material comprising a cementitious material having opposed generally planar surfaces and opposed edges; and

(ii) at least one scrim disposed on top of at least one of the opposed generally planar surfaces or within the matrix material, said scrim comprising a mesh of inorganic fibers defining a plurality of cross-points and a plurality of open spaces, said inorganic fibers comprising a solidified plastisol coating layer comprising a plastisol composition comprising (i) a plasticizer;

(ii) a polymeric resin; and

(iii) one or more hydrolyzable organosilicon compounds (“

HOC”

), said coating layer being indirectly or directly at least partially coated onto the inorganic fibers.

38. The reinforced cementitious board according to claim 37, wherein the inorganic fibers are substantially completely coated with the plastisol coating layer.

39. The reinforced cementitious board according to claim 37, wherein the plastisol coating layer is positioned directly onto the inorganic fibers such that that plastisol coating layer is directly adjacent the inorganic fibers.

40. The reinforced cementitious board according to claim 37, wherein the inorganic fibers further comprise a sizing composition positioned directly adjacent the inorganic fibers and sandwiched between the inorganic fibers and the plastisol coating layer.

41. The reinforced cementitious board according to claim 40, wherein the sizing composition includes one or more silanes, organosilanes, or polysiloxanes.

42. The reinforced cementitious board according to claim 40, wherein the sizing composition is devoid of one or more silanes, organosilanes, or polysiloxanes.

43. The reinforced cementitious board according to claim 37, wherein the inorganic fibers comprise individual single strands.

44. The reinforced cementitious board according to claim 37, wherein the inorganic fibers comprise yarn of multiple inorganic filaments.

45. The reinforced cementitious board according to claim 37, wherein the inorganic filaments comprise fiberglass.

46. The reinforced cementitious board according to claim 37, wherein the inorganic fibers comprises fiberglass.