Joint compound composition for building elements and method of producing a structure

• US 7,594,963 B2
• Filed: 11/07/2003
• Issued: 09/29/2009
• Est. Priority Date: 11/08/2002
• Status: Active Grant

• Current Assignee: Continental Building Products Operating Company, Llc (Compagnie de Saint-Gobain SA)
• Original Assignee: Lafarge Platres (Holcim Limited)
• Inventors: Bonetto, Christian, Domenech, Marc, Petit, Alain
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US10/534,231
• Publication Number:
  US 20060048684A1
• Time in Patent Office: 2,153 Days
• Field of Search: 106/2, 106/772, 106/778
• US Class Current: 106/778
• CPC Class Codes: C04B 14/185 expanded
• 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 2103/0091 Organic co-binders for mineral binder compositions
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 2111/00689 of the setting type
• CPC Class Codes: C04B 24/085 Higher fatty acids
• CPC Class Codes: C04B 24/26 obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 24/34 Natural resins, e.g. rosin C04B24/243 takes precedence
• CPC Class Codes: C04B 24/42 Organo-silicon compounds
• CPC Class Codes: C04B 28/146 alpha-hemihydrate
• 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
• CPC Class Codes: E04F 13/04 Bases for plaster sub-ceilings with plaster-carrying means E04B9/06

Abstract

The present invention relates to a joint compound composition for building elements, particularly paper-faced plasterboards.

This composition comprises:

• • a) 50 to 60% of calcium sulphate hemihydrate;
  • b) 5 to 15% of an organic binder in powder form; and
  • c) 0.05 to 0.2% of a water repellent.

The invention also relates to a method producing a structure, such as a partition, a wall trim or a ceiling.

According to this method:

• • building elements are juxtaposed;
  • the joint compound composition according to the invention is mixed with water so as to obtain a joint compound;
  • the space between the building elements is filled by means of the joint compound obtained above, without using a tape; and
  • the joint compound is left to harden.

Claims

1. A joint compound composition comprising:

a) 50 to 60% of calcium sulphate hemihydrate;

b) 5 to 15% of an organic binder in powder form; and

c) 0.05 to 0.2% of a water repellent selected from the group consisting of oleic acid, stearic acid and their alkali metal or alkaline earth metal salt.

2. The joint compound composition according to claim 1, which further includes:

d) 1 to 10% of a lightening agent.

3. The joint compound composition according to claim 1, wherein the composition comprises 5 to 10% of the organic binder;

0.07 to 0.15% of the water repellent; and

3 to 7% of a lightening agent.

4. The joint compound composition according to claim 1, wherein the calcium sulphate hemihydrate is of the alpha form.

5. The joint compound composition according to claim 1, wherein the organic binder is selected from the group consisting of copolymers of vinyl esters and of ethylene monomers, polyacrylics, vinyl acetate/acrylic copolymers, styrene/acrylic and styrene/butadiene copolymers, vinyl acetate/vinyl versatate/acrylic and vinyl acetate/vinyl versatate/vinyl maleate terpolymers, acrylic terpolymers and blends thereof.

6. The joint compound composition according to claim 2, wherein the lightening agent is perlite.

7. The joint compound composition according to claim 2, wherein the lightening agent is non-water-repellent expanded perlite.

8. The joint compound composition according to claim 1, wherein the composition is in the form of a powder.

9. The joint compound composition according to claim 1, wherein the composition is in the form of a powder composed of particles having a diameter of at most 200 microns.

10. The joint compound composition according to claim 1, wherein the water repellent is selected from the group consisting of oleic acid and its alkali metal or alkaline earth metal salt.