POLYURETHANE POWDER BLEND WITH REDISPERSIBLE POLYMER POWDER FOR CEMENT COMPOSITIONS

• US 20140275307A1
• Filed: 10/24/2012
• Published: 09/18/2014
• Est. Priority Date: 10/28/2011
• Status: Abandoned Application

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Dombrowski, Juergen, Kuehn, Hartmut, Perello, Margarita, Scharlemann, Sonja
• Application Number:
  US14/353,818
• Publication Number:
  US 20140275307A1
• Time in Patent Office: Days
• US Class Current: 521/137
• CPC Class Codes: C04B 16/082 other than polystyrene based, e.g. polyurethane foam
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/00646 Masonry mortars
• CPC Class Codes: C04B 2111/00672 Pointing or jointing materials
• CPC Class Codes: C04B 2111/00741 Preventing erosion
• CPC Class Codes: C04B 2111/62 Self-levelling compositions
• CPC Class Codes: C04B 2111/72 Repairing or restoring existing buildings or building materials
• CPC Class Codes: C04B 24/2611 Polyalkenes
• CPC Class Codes: C04B 24/2623 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2676 Polystyrenes
• CPC Class Codes: C04B 24/282 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0042 Powdery mixtures
• CPC Class Codes: C09K 8/467 containing additives for specific purposes

Abstract

Powdered polyurethane flexible foams, preferably powdered recycled polyurethane flexible foams are used with a redispersible polymer powder (RDP), preferably as a preblended additive, in hydraulic binders or cementitious compositions to improve performance of cementitious compositions or mortar, in applications such as cement based tile adhesives (CBTA), or external thermal insulating composite systems (ETICS). The use of the powdered polyurethane flexible foam as a partial replacement for an RDP unexpectedly provides an increase in wet mortar density while maintaining excellent workability and quick open time, quicker setting times, improved impact resistance, and increased adhesion after water immersion.

Claims

1. An additive for a hydraulic binder, the additive comprising a preblend of a powdered polyurethane flexible foam and a water redispersible polymer powder (RDP), said water redispersible polymer powder comprising a water insoluble film-forming polymer, the amount of the powdered polyurethane flexible foam being from 10% by weight to 80% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder.

2. An additive as claimed in claim 1 wherein the powdered polyurethane flexible foam is a ground recycled flexible polyurethane foam having an average particle size of from 5 microns to 500 microns.

3. An additive as claimed in claim 2 wherein the redispersible polymer powder has an average particle size of from 5 to 150 microns.

4. An additive as claimed in claim 1 wherein the water insoluble film-forming polymer comprises a polymer prepared from a styrene butadiene copolymer, a styrene butadiene copolymerized with another comonomer, a vinylacetate ethylene (VAE) copolymer, a VAE/VA-VeoVA copolymer mixture, a polyurethane, a polyolefin, cellulose, a cellulose ether or a modified cellulose.

5. An additive as claimed in claim 1 wherein the water insoluble film-forming polymer comprises a polymer prepared from a styrene-butadiene copolymer, or a styrene butadiene copolymerized with another copolymer, or a vinylacetate-ethylene copolymer.

6. An additive as claimed in claim 2 wherein the amount of the powdered polyurethane flexible foam is from 20% by weight to 70% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder, and the powdered polyurethane flexible foam has an average particle size of from 20 microns to 150 microns.

10. A dry mix composition comprising cement ingredients and an additive as claimed in claim 1 in an amount of at least 0.1% by weight, based upon the weight of the dry mix formulation.

7. A method for producing an additive for a hydraulic binder comprising dry blending a powdered polyurethane flexible foam and a water redispersible polymer powder (RDP), said water redispersible polymer powder comprising a water insoluble film-forming polymer, the amount of the powdered polyurethane flexible foam being from 10% by weight to 80% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder, the powdered polyurethane flexible foam having an average particle size of from 5 microns to 500 microns, and the redispersible polymer powder having an average particle size of from 5 to 150 microns.

8. A method for producing an additive as claimed in claim 7 wherein the water insoluble film-forming polymer comprises a polymer prepared from a styrene butadiene copolymer, a styrene butadiene copolymerized with another comonomer, a vinylacetate ethylene (VAE) copolymer, a VAE/VA-VeoVA copolymer mixture, a polyurethane, a polyolefin, a cellulose, or a cellulose derivative, the amount of the powdered polyurethane flexible foam is from 20% by weight to 70% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder, and the powdered polyurethane flexible foam has an average particle size of from 20 microns to 150 microns.

9. A method for making a hydraulic binder comprising admixing cement ingredients with a powdered polyurethane flexible foam and a water redispersible polymer powder (RDP), said water redispersible polymer powder comprising a water insoluble film-forming polymer, the amount of the powdered polyurethane flexible foam being from 10% by weight to 80% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder.

11. A dry mix composition comprising cement ingredients, a powdered polyurethane flexible foam, and a water redispersible polymer powder (RDP), said water redispersible polymer powder comprising a co-dried admixture of a water insoluble film-forming polymer and a colloidal stabilizer, the amount of the powdered polyurethane flexible foam being from 10% by weight to 80% by weight, based upon the total weight of the powdered polyurethane flexible foam and the water redispersible polymer powder, and the total amount of the powdered polyurethane flexible foam and the water redispersible polymer powder being from 0.1% by weight to 10% by weight, based upon the weight of the dry mix formulation.