Low-Dust Products Using Microcrystalline Wax Emulsion

• US 20200131411A1
• Filed: 08/05/2019
• Published: 04/30/2020
• Est. Priority Date: 09/24/2015
• Status: Active Grant

• Current Assignee: Henry Company LLC (Carlisle Cos., Inc.)
• Original Assignee: Henry Company LLC (Carlisle Cos., Inc.)
• Inventors: Ayambem, Amba, Kent, Daniel
• Granted Patent: US 11,186,752 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: C08K 5/01 Hydrocarbons C08K5/0091 takes precedence
• CPC Class Codes: C09D 5/34 Filling pastes materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12
• CPC Class Codes: C09J 11/06 organic
• CPC Class Codes: C09J 11/08 Macromolecular additives
• CPC Class Codes: C09J 129/04 Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: C09J 2301/408 additives as essential feature of the adhesive layer
• CPC Class Codes: C09J 5/00 Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: C09J 9/00 Adhesives characterised by their physical nature or the effects produced, e.g. glue sticks C09J7/00 takes precedence
• CPC Class Codes: C09K 3/10 Materials in mouldable or extrudable form for sealing or packing joints or covers filling pastes C09D5/34
• CPC Class Codes: C09K 3/22 for dust-laying or dust-absorbing

Abstract

The present invention relates generally to wall repair compounds such as joint compounds, spackling compounds, and the like used to repair imperfections in walls or fill joints between adjacent wallboard panels. Particularly, the present invention relates to such a wall repair compound comprising a dust reducing additive that reduces the quantity of airborne dust generated when the hardened compound is sanded. The dust reducing additive also imparts adhesion to the wall repair compounds to which it is added, for example to a joint compound. The dust reducing additive comprises microcrystalline-wax based emulsion.

Claims

1. A method of using a first low-dust, wall-repair compound composition that has low-dust property and optionally improved adhesive property and/or improved water resistance property, said method comprising:

(I) applying said composition to a wallboard panel;

(II) allowing said composition to dry; and

(III) sanding said dried composition;

wherein said wall repair composition comprises a dust reduction additive emulsion comprising colloidally-protected microcrystalline wax-based (CMWB) microstructure, comprising;

(A) a wax core, wherein said wax core comprises a micro-crystalline wax component and optionally a non-micro-crystalline wax component, wherein said microcrystalline wax component comprises at least one linear alkane wax defined by the general formula C_nH_2n+2, where n ranges from 13-80, wherein said non-microcrystalline wax component comprises at least one wax selected from the group consisting of animal-based wax, plant-based wax, mineral wax, synthetic wax, a wax containing organic acids and/or esters, anhydrides, an emulsifier containing a mixture of organic acids and/or esters, and combinations thereof;

(B) a polymeric shell, wherein said polymeric shell comprises at least one polymer selected from polyvinyl alcohol, polyvinyl alcohol copolymers, polyvinyl alcohol terpolymers, polyvinyl acetate, polyvinyl acetate copolymers, polyvinyl acetate terpolymers, cellulose ethers, polyethylene oxide, polyethyleneimines, polyvinylpyrrolidone, polyvinylpyrrolidone copolymers, polyethylene glycol, polyacrylamides and poly (N-isopropylamides), pullulan, sodium alginate, gelatin, starches, and combinations thereof; and

optionally

(C) at least one component selected from the group consisting of a silicone, a siliconate, a fluorinated compound, a stearate, or a combination thereof.

2. The method as recited in claim 1, wherein said first low-dust, wall-repair compound is a joint compound or a spackling compound.

3. The method as recited in claim 1, wherein the weight of said dust reduction additive emulsion is in the range of from about 0.1% to about 20% by weight of said first lowdust, wall-repair compound composition.

4. The method as recited in claim 3, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound.

5. The method as recited in claim 1, wherein said polymeric shell comprises polyvinyl alcohol.

6. The method as recited in claim 5, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound.

7. The method as recited in claim 1, wherein said dust-reduction additive emulsion further comprises a base and a dispersant.

8. The method as recited in claim 1, wherein the silicones, siliconates, fluorinated compounds, or stearates are selected from the group consisting of metal siliconate salts, potassium siliconate, poly hydrogen methyl siloxane, polydimethyl siloxane, stearate-based salts, and combinations thereof.

9. The method as recited in claim 8, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound.

10. The method as recited in claim 1, wherein the quantity of dust generated upon sanding of said first low-dust, wall-repair compound composition is reduced at least by 5% of the quantity of dust generated upon sanding of a second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

11. The method as recited in claim 10, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

12. The method as recited in claim 1, wherein the quantity of dust generated upon sanding of said first low-dust, wall-repair compound composition is reduced at least by 80% of the quantity of dust generated upon sanding of a second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

13. The method as recited in claim 12, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

14. The method as recited in claim 1, wherein the quantity of dust generated upon sanding of said first low-dust, wall-repair compound composition is reduced at least by 80% of the quantity of dust generated upon sanding of a second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

15. The method as recited in claim 14, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

16. A method for reducing the quantity of dust generated by a wall-repair-compound composition, said method comprising the steps of:

(I) providing a wall-repair-compound composition comprising a filler, a first water, binder, and at least one of a defoamer, wetting agent, preservative, fungicide, thickener, non-leveling agent, surfactant, and a solvent; and

(II) subsequently adding a sufficient quantity of a dust-reduction additive emulsion as recited in claim 11 to said first low-dust, wall-repair compound composition to reduce the quantity of dust generated by sanding said hardened low-dust, wallrepair compound composition by at least 5% of the quantity of dust generated upon sanding of a second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

17. The method as recited in claim 16, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

18. The method for reducing the quantity of dust generated by a joint-compound as recited in claim 15, wherein the quantity of dust generated by sanding said hardened drywall comprising said first low-dust, wall-repair compound is reduced by at least 80% of the quantity of dust generated upon sanding of said second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

19. The method as recited in claim 18, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

20. The method for reducing the quantity of dust generated by a joint-compound as recited in claim 15, wherein the quantity of dust generated by sanding said hardened drywall comprising said first low-dust, wall-repair compound is reduced by at least 80% of the quantity of dust generated upon sanding of said second wall-repair compound composition having the same composition as said first low-dust, wall-repair compound, but not comprising said dust reduction additive.

21. The method as recited in claim 20, wherein said first low-dust, wall-repair compound is a first joint compound or a first spackling compound;

and said second wall-repair compound is a second joint compound or a second spackling compound.

22. The method as recited in claim 12, wherein said first low-dust, wall-repair compound composition has a contact angle of about 60°

to about 150°

; and

/or wherein said first low-dust, wall-repair compound composition has a Cobb value of about 5.0 to about 100 g/m².

23. The method as recited in claim 22, wherein said first wall-repair compound is a first joint compound or a first spackling compound.