Joint compound, wall assembly, and methods and products related thereto
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E04F-013/02
E04F-013/04
E04F-013/08
C08K-007/28
C04B-026/06
C04B-026/14
C04B-026/16
C04B-026/18
C08L-033/08
E04F-013/06
C04B-103/00
C04B-111/00
C04B-111/10
출원번호
US-0492905
(2014-09-22)
등록번호
US-9140015
(2015-09-22)
발명자
/ 주소
Negri, Robert H.
Miklosz, Mark
Hargrove, Pamela
Bury, Rafael
출원인 / 주소
United States Gypsum Company
대리인 / 주소
Greer, Burns & Crain, Ltd.
인용정보
피인용 횟수 :
2인용 특허 :
20
초록
A kit for assembling walls and ceilings is provided. The kit comprises at least two gypsum boards, each with at least one tapered edge, and a self-drying joint compound comprising a polymeric binder and hollow spheres. Methods for wall and ceiling installation are provided as well.
대표청구항▼
1. A kit for assembling at least one of the following: a wall and a ceiling, the kit comprising: (a) at least two gypsum boards, each of the boards having at least one tapered edge with a recess depth at the deepest point in the range from about 0.005 inch to about 0.125 inch; and(b) a drying-type j
1. A kit for assembling at least one of the following: a wall and a ceiling, the kit comprising: (a) at least two gypsum boards, each of the boards having at least one tapered edge with a recess depth at the deepest point in the range from about 0.005 inch to about 0.125 inch; and(b) a drying-type joint compound with shrinkage of less than 15% by volume as measured by ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof;wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and wherein the density of the spheres is from about 0.0015 lb/in3 (about 0.04 g/cm3) to about 0.04 lb/in3 (about 1.1 g/cm3). 2. The kit of claim 1, wherein the binder in the joint compound is an acrylic acid polymer or acrylic acid copolymer. 3. The kit of claim 1, wherein the binder in the joint compound is in the form of an aqueous emulsion. 4. The kit of claim 1, wherein the joint compound has a density from about 2 lb/gal to about 8 lb/gal. 5. The kit of claim 1, wherein the joint compound exhibits shrinkage of about 2% or less by volume, as measured by ASTM C474-05. 6. The kit of claim 1, wherein the joint compound is substantially free of at least one of the following: setting minerals, bulk filler, clays, starch, mica, calcium carbonate, expanded perlite, calcium magnesium carbonate, limestone, calcium sulfate dihydrate, attapulgite clay, kaolin clay, talcs and diatomaceous earth. 7. The kit of claim 1, wherein the binder in the joint compound has a glass transition temperature (Tg) from about 32° F. to about 70° F. 8. The kit of claim 1, wherein the hollow spheres are made from a material selected from the group consisting of lime boro-silicate, polystyrene, ceramic, recycled glass, expanded glass, lightweight polyolefin, and any combination thereof. 9. The kit of claim 1, wherein the joint compound further comprises a nonionic surfactant having a hydrophilic-lipophilic balance (HLB) from about 3 to about 20. 10. The kit of claim 1, wherein the kit further comprises at least one or more of the following: a framing member, adhesive, reinforcement trim and joint tape. 11. A method for assembling at least one of the following: a wall and a ceiling, the method comprising: (a) obtaining a first gypsum board and a second gypsum board, each of the boards having at least one tapered edge with a recess depth at the deepest point in the range from about 0.005 inch to about 0.125 inch;(c) obtaining a drying-type joint compound with shrinkage of less than 15% by volume as measured by ASTM C474-05, the drying-type joint compound comprising a plurality of hollow spheres and a binder selected from the group consisting of acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, and combinations thereof; wherein the hollow spheres have an average isostatic crush strength of at least about 250 psi as measured according to ASTM D3102-78; and wherein the density of the spheres is from about 0.0015 lb/in3 (about 0.04 g/cm3) to about 0.04 lb/in3 (about 1.1 g/cm3);(d) joining the two gypsum boards together such that the tapered edges of the two boards create a seam; and(e) applying the drying-type joint compound over the seam. 12. The method of claim 11, wherein the drying-type joint compound is applied in one coat only. 13. The method of claim 11, wherein the seam between the first gypsum board and the second gypsum board is further reinforced with a joint tape. 14. The method of claim 11, wherein at least one of the first gypsum board and the second gypsum board comprises a gypsum core sandwiched between two sheets of paper. 15. The method of claim 11, wherein each of the first gypsum board and the second gypsum board has a face surface and a back surface, and wherein the face surface of the first gypsum board and the face surface of the second gypsum board have at least one tapered edge, while the back surfaces are not tapered. 16. The method of claim 15, wherein the two gypsum boards are joined at the tapered edges to create a seam such that the two face surfaces stay on the same side and create a combined face surface, and the joint compound is applied over the seam on the combined face surface only. 17. The method of claim 11, wherein the method is performed in less than 48 hours. 18. The method of claim 11, wherein the method is performed in less than 24 hours. 19. The method of claim 11, wherein the method is performed in less than 72 hours. 20. The method of claim 11, wherein the step of applying the joint compound to the seam creates a substantially flat surface.
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