Joint compounds using thickeners prepared from raw cotton linters

• US 20050235878A1
• Filed: 04/25/2005
• Published: 10/27/2005
• Est. Priority Date: 04/27/2004
• Status: Active Grant

• Current Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.)
• Original Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.)
• Inventors: Podlas, Thomas J.
• Granted Patent: US 7,066,996 B2
• Time in Patent Office: Days
• US Class Current: 106/618
• CPC Class Codes: B63H 3/008 characterised by self-adjusting pitch, e.g. by means of springs, centrifugal forces, hydrodynamic forces
• CPC Class Codes: C04B 14/102 Attapulgite clay
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/365 Gypsum synthetic gypsum C04B18/0445, C04B18/064
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2103/0086 Chelating or complexing agents
• CPC Class Codes: C04B 2103/0099 Aspecific ingredients, i.e. high number of alternative specific compounds mentioned for the same function or property
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2103/304 Air-entrainers
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 2111/00672 Pointing or jointing materials
• CPC Class Codes: C04B 2201/10 for the viscosity
• CPC Class Codes: C04B 24/10 Carbohydrates or derivatives thereof
• CPC Class Codes: C04B 24/223 : Sulfonated melamine-formaldehyde condensation products
• CPC Class Codes: C04B 24/226 : Sulfonated naphtalene-formaldehyde condensation products
• CPC Class Codes: C04B 24/2623 : Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2647 : containing polyether side chains
• CPC Class Codes: C04B 24/2652 : Nitrogen containing polymers, e.g. polyacrylamides, polyacrylonitriles
• CPC Class Codes: C04B 24/32 : Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 26/02 : Macromolecular compounds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/0039 : Premixtures of ingredients
• 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: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A mixture composition of a cellulose ether made from raw cotton linters and at least one additive is used in a ready mixed joint compound composition wherein the amount of the cellulose ether in the joint compound composition is significantly reduced. When this joint compound composition is mixed with water and applied to a substrate, the water retention, sag resistance, and workability of the wet joint compound are comparable or improved as compared to when using conventional similar cellulose ethers.

Claims

1. A mixture composition for use in joint compound comprising

a) a cellulose ether in an amount of 20 to 99.9 wt % selected from the group consisting of alkylhydroxyalkyl celluloses and hydroxyalkyl celluloses and mixtures thereof, prepared from raw cotton linters, and

b) at least one additive in an amount of 0.1 to 80 wt % selected form the group consisting of organic or inorganic thickening agents, anti-sag agents, air entraining agents, wetting agents, defoamers, dispersants, calcium-complexing agents, retarders, accelerators, redispersible powders, biopolymers, and fibres,

wherein when the mixture composition is used in a joint compound formulation and is mixed with a sufficient amount of water, the joint compound formulation produces a paste that can be applied to substrates, wherein the amount of the mixture in the joint compound is significantly reduced while water retention, sag-resistance, and workability of the wet joint compound are improved or comparable as compared to when using conventional similar cellulose ethers.

2. The mixture composition of claim 1, wherein the alkyl group of the alkylhydroxyalkyl celluloses has 1 to 24 carbon atoms and the hydroxyalkyl group has 2 to 4 carbon atoms.

3. The mixture composition of claim 1 wherein the cellulose ether is selected from the group consisting of methylhydroxyethylcelluloses (MHEC), methylhydroxypropylcelluloses (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcelluloses (EHEC), methylethylhydroxyethylcelluloses (MEHEC), hydrophobically modified ethylhydroxyethylcelluloses (HMEHEC), hydrophobically modified hydroxyethylcelluloses (HMHEC) and mixtures thereof.

4. The mixture composition of claim 1, wherein the mixture also comprises one or more conventional cellulose ethers selected from the group consisting of methylcellulose (MC), methylhydroxyethylcellulose (MHEC), methylhydroxypropylcellulose (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcellulose (EHEC), hydrophobically modified hydroxyethylcellulose (HMHEC), hydrophobically modified ethylhydroxyethylcellulose (HMEHEC), methylethylhydroxyethylcellulose (MEHEC), sulfoethyl methylhydroxyethylcelluloses (SEMHEC), sulfoethyl methylhydroxypropylcelluloses (SEMHPC), and sulfoethyl hydroxyethylcelluloses (SEHEC).

5. The mixture composition of claim 1, wherein the amount of the cellulose ether is 70 to 99.9 wt.

6. The mixture composition of claim 1, wherein the amount of the at least one additive is 0.5 to 30 wt %

7. The mixture composition of claim 3, wherein the cellulose ether, where applicable, has a methyl or ethyl degree of substitution of 0.5 to 2.5, hydroxyethyl or hydroxypropyl molar substitution (MS) of 0.01 to 6, and molar substitution (MS) of the hydrophobic substituents of 0.01-0.5 per anhydroglucose unit.

8. The mixture composition of claim 1, wherein the at least one additive is an organic thickening agent selected from the group consisting of starch ether, starch, guar, guar derivatives, xanthan gum, welan gum, gellan gum, carrageenan, alginate, and cellulose fibres.

9. The mixture composition of claim 1, wherein the at least one additive is selected from the group consisting of homo- or co-polymers of acrylamide, polyethylene glycol, casein, naphthalene-sulfonate, sulfonated melamine-formaldehyde condensate, sulfonated naphthalene-formaldehyde condensate, polyacrylates, polycarboxylate ether, phosphates, phosphonates, bentonite, montmorillonite, sepiolite, and homo-, co-, or terpolymers based on vinyl acetate, maleic ester, ethylene, butadiene, vinyl versatate, and acrylic monomers.

10. The mixture composition of claim 3 is MHEC and a guar derivative.

11. The mixture composition of claim 10, wherein the guar derivative is selected from the group consisting of hydroxypropyl guar, methylhydroxypropyl guar, carboxymethyl guar, carboxymethylhydroxypropyl guar, cationically modified guar and mixtures thereof.

12. The mixture composition of claim 3 is MHPC and a guar derivative.

13. The mixture composition of claim 12, wherein the guar derivative is selected from the group consisting of hydroxypropyl guar, methylhydroxypropyl guar, carboxymethyl guar, carboxymethylhydroxypropyl guar, cationic guar and mixtures thereof.

14. The mixture composition of claim 3 is HMHEC and a guar derivative.

15. The mixture composition of claim 14, wherein the guar derivative is selected from the group consisting of hydroxypropyl guar, methylhydroxypropyl guar, carboxymethyl guar, carboxymethylhydroxypropyl guar, cationically modified guar and mixtures thereof.

16. The mixture composition of claim 1, wherein the cellulose ether has a 2% aqueous solution Brookfield viscosity of greater than 80,000 mPas as measured on a Brookfield RVT viscometer at 20°

C. and 20 rpm, using a spindle number 7.

17. The mixture composition of claim 1, wherein the cellulose ether has a 2% aqueous solution Brookfield viscosity of greater than 90,000 mPas as measured on a Brookfield RVT viscometer at 20°

C. and 20 rpm, using a spindle number 7.

18. The mixture composition of claim 1, wherein the significantly reduced amount of the mixture used in the joint compound paste is at least 5% reduction.

19. The mixture composition of claim 1, wherein the significantly reduced amount of the mixture used in the joint compound paste is at least 10% reduction.

20. A ready mixed, joint compound composition comprising a binder, filler, biocide, and a thickener and water-retaining agent of at least one cellulose ether prepared from raw cotton linters,

wherein when the ready mixed joint compound composition is mixed with a sufficient amount of water, the joint compound composition produces a joint compound paste where the amount of the cellulose ether in the joint compound is significantly reduced while water retention, sag resistance, and workability of the joint compound mortar are improved or comparable as compared to when using conventional similar cellulose ethers.

21. The ready-mixed joint compound composition of claim 20, wherein the cellulose ether is selected from the group consisting of alkylhydroxyalkyl celluloses and hydroxyalkyl celluloses and mixtures thereof.

22. The ready-mixed joint compound composition of claim 21, wherein the alkyl group of the alkylhydroxyalkyl celluloses has 1 to 24 carbon atoms and the hydroxyalkyl group has 2 to 4 carbon atoms.

23. The ready-mixed joint compound composition of claim 20, wherein the at least one cellulose ether is selected from the group consisting of methylhydroxyethylcelluloses (MHEC), methylhydroxypropylcelluloses (MHPC), hydroxyethylcelluloses (HEC), methylethylhydroxyethylcelluloses (MEHEC), ethylhydroxyethylcelluloses (EHEC), hydrophobically modified ethylhydroxyethylcelluloses (HMEHEC), hydrophobically modified hydroxyethylcelluloses (HMHEC) and mixtures thereof.

24. The ready-mixed joint compound composition of claim 23, wherein the cellulose ether, where applicable, has a methyl or ethyl degree of substitution of 0.5 to 2.5, hydroxyethyl or hydroxypropyl molar substitution (MS) of 0.01 to 6, and molar substitution (MS) of the hydrophobic substituents of 0.01-0.5 per anhydroglucose unit.

25. The ready-mixed joint compound composition of claim 20, wherein the joint compound composition also comprises one or more conventional cellulose ethers selected from the group consisting of methylcellulose (MC), methylhydroxyethylcellulose (MHEC), methylhydroxypropylcellulose (MHPC), hydroxyethylcellulose (HEC), ethylhydroxyethylcellulose (EHEC), hydrophobically modified hydroxyethylcellulose (HMHEC), hydrophobically modified ethylhydroxyethylcellulose (HMEHEC), methylethylhydroxyethylcellulose (MEHEC), sulfoethyl methylhydroxyethylcelluloses (SEMHEC), sulfoethyl methylhydroxypropylcelluloses (SEMHPC), and sulfoethyl hydroxyethylcelluloses (SEHEC).

26. The ready-mixed joint compound composition of claim 20, wherein the amount of cellulose ether is from 0.001 to 2 wt %.

27. The ready-mixed joint compound composition of claim 20, in combination with at least one additive selected form the group consisting of organic or inorganic thickening agents, anti-sag agents, air entraining agents, wetting agents, defoamers, dispersants, calcium-complexing agents, retarders, accelerators, redispersible powders, biopolymers, and fibres,

28. The ready-mixed joint compound composition of claim 27, wherein the additive is the organic thickening agent selected from the group consisting of starch ether, starch, guar, guar derivatives, xanthan gum, welan gum, gellan gum, carrageenan, alginate, and cellulose fibres.

29. The ready-mixed joint compound composition of claim 27, wherein the at least one additive is selected from the group consisting of homo- or co-polymers of acrylamide, polyethylene glycol, casein, naphthalene-sulfonate, sulfonated melamine-formaldehyde condensate, sulfonated naphthalene-formaldehyde condensate, polyacrylates, polycarboxylate ether, phosphates, phosphonates, bentonite, montmorillonite, sepiolite, and homo-, co-, or terpolymers based on vinyl acetate, maleic ester, ethylene, butadiene, vinyl versatate, and acrylic monomers.

30. The ready-mixed joint compound composition of claim 23, wherein the cellulose ether is selected from the group consisting of MHEC, MHPC, HMHEC, and mixtures thereof and a guar derivative additive is present.

31. The ready-mixed joint compound composition of claim 30, wherein the guar derivative is selected from the group consisting of hydroxypropyl guar, methylhydroxypropyl guar, carboxymethyl guar, carboxymethylhydroxypropyl guar, cationically modified guar and mixtures thereof.

32. The ready-mixed joint compound composition of claim 23, wherein the cellulose ether has a 2% aqueous solution Brookfield viscosity of greater than 80,000 mPas as measured on a Brookfield RVT viscometer at 20°

C. and 20 rpm, using a spindle number 7.

33. The ready-mixed joint compound composition of claim 23, wherein the cellulose ether has a 2% aqueous solution Brookfield viscosity of greater than 90,000 mPas as measured on a Brookfield RVT viscometer at 20°

C. and 20 rpm, using a spindle number 7.

34. The ready-mixed joint compound composition of claim 20, wherein the binder is selected from the group consisting of ethylene vinyl acetate latex, poly (vinyl acetate) latex, starch, casein, polyacrylamide and copolymers of acrylamide and acrylic acid.

35. The ready-mixed joint compound composition of claim 20, wherein the binder is present in the amount of lower limit of 1 wt % and an upper limit of 5 wt %.

36. The ready-mixed joint compound composition of claim 35, wherein the binder is present in the amount of an upper limit of 2.5 wt %.

37. The ready-mixed joint compound composition of claim 20, wherein the filler is selected from the group consisting of calcium carbonate, calcium sulfate dihydrate, and dolomitic limestone, and mixtures thereof.

38. The ready-mixed joint compound composition of claim 37, wherein the filler also contains calcium sulfate hemihydrate.

39. The ready-mixed joint compound composition of claim 20, wherein a pH modifier is present in order to maintain a pH of 8 to 10.

40. The ready-mixed joint compound composition of claim 20, wherein clay or mica or mixtures thereof are present.

41. The ready-mixed joint compound composition of claim 40, wherein mica is only present.

42. The ready-mixed joint compound composition of claim 40, wherein clay is only present.

43. The ready-mixed joint compound composition of claim 40, wherein a mixture of clay and mica is present.

44. The ready-mixed joint compound composition of claim 40, wherein the clay is selected from the group consisting of sepiolite, montmorillonite, bentonite, illite, kaolin, and attapulgite.

45. The ready-mixed joint compound composition of claim 42, wherein the clay is attapulgite.

46. The ready-mixed joint compound composition of claim 40, wherein the clay is present in the amount upper limit of 0.5 weight %.

47. The ready-mixed joint compound composition of claim 40, wherein the clay is present in the amount upper limit of 0.75 weight %.

48. The ready-mixed joint compound composition of claim 40, wherein the clay is present in the amount upper limit of 3.5 weight %.

49. The ready-mixed joint compound composition of claim 40, wherein the mica amount has an upper limit of 5.0 weight %.

50. The ready-mixed joint compound composition of claim 20, wherein perlite is present.

51. The ready-mixed joint compound composition of claim 50 wherein the perlite amount has an upper limit of 8 weight %.

52. The ready-mixed joint compound composition of claim 20, wherein the density of the composition is 8 to 10 pounds per gallon (ppg).

53. The ready-mixed joint compound composition of claim 20, wherein the density of the composition is 12 to 14 ppg.

54. The ready-mixed joint compound composition of claim 20, wherein the significantly reduced amount of the cellulose ether used in the joint compound paste is at least 5% reduction.

55. The ready-mixed joint compound composition of claim 20, wherein the significantly reduced amount of the cellulose ether used in the joint compound paste is at least 10% reduction.