COMPOSITION FOR A VERY DURABLE PASTY FILL AND FINISHING MATERIAL, PASTY FILL AND FINISHING MATERIAL, AND METHOD FOR PRODUCING IT

Abstract

The invention relates to a composition for a pasty fill and finishing material, a pasty fill and finishing material, and a method for producing a pasty fill and finishing material. The composition comprises at least one filler, at least one binding agent, and additives, wherein the at least one binding agent comprises an organic polymer and hydroxyethyl cellulose, and wherein the at least one filler is a lamellar silicate material.

Claims

1. A composition for a pasty fill and finishing material, comprising at least one filler, at least one binding agent, and additives, wherein the at least one binding agent comprises an organic polymer and hydroxyethyl cellulose, and wherein the at least one filler is a lamellar silicate material.

2. The composition according to claim 1, wherein the organic polymer is selected from a group consisting of poly(ethylene-vinyl acetate), polyvinyl acetate, polyacrylate, or any combinations thereof.

3. The composition according to claim 1, wherein the composition comprises 0.1 to 20% by weight of the total composition of the at least one binding agent.

4. The composition according to claim 1, wherein the at least one binding agent comprises 0.001 to 0.20% by weight of the total composition of the hydroxyethyl cellulose.

5. The composition according to claim 1, wherein the lamellar silicate material is selected from a group consisting of sepiolite, attapulgite, talc, montmorillonite, illite, kaolinite or hectorite.

6. The composition according to claim 1, wherein the composition comprises 0.01 to 1.00% by weight of the total composition of the lamellar silicate material.

7. The composition according to claim 1, wherein the lamellar silicate material contains magnesium and/or aluminum.

8. The composition according to claim 1, wherein the composition further comprises cellulose.

9. The composition according to claim 8, wherein the composition comprises 0.1 to 2.0% by weight of the total composition of cellulose.

10. The composition according to claim 9 wherein the composition comprises 0.01 to 0.2% by weight of the total composition of hydroxypropyl methyl cellulose and 0.35 to 0.6% by weight of the total composition of hydroxyethyl cellulose.

11. The composition according to claim 1, wherein the composition comprises at least two fillers, wherein the first filler is a lamellar silicate material and the second further filler is selected from the group consisting of calcium sulfate dihydrate, calcium carbonate, calcium magnesium carbonate and any combination thereof.

12. The composition according to claim 11, wherein the composition comprises at least a third filler, wherein the third filler is a mica mineral.

13. The composition according to claim 1, wherein the composition further comprises biocides.

14. A pasty fill and finishing material, in particular physically drying sprayable fill and finishing material, prepared from the composition according to claim 1.

15. A method for producing a pasty fill and finishing material, in particular a pasty fill and finishing material according to claim 14, wherein the method is based on a two-stage process, according to which in a first step dry components are homogenized, and in a second step, the homogenized dry components are added to aqueous or water-dilutable components.

16. The composition according to claim 1, wherein the organic polymer comprises poly(ethylene-vinyl acetate) and/or the lamellar silicate material comprises sepiolite.

17. The composition according to claim 1, wherein the composition comprises 3 to 15% by weight of the total composition of the at least one binding agent.

18. The composition according to claim 1, wherein the at least one binding agent comprises 0.001 to 0.10% by weight of the total composition of the hydroxyethyl cellulose.

19. The composition according to claim 1, wherein the composition comprises 0.03 to 0.50% by weight of the total composition composition of the lamellar silicate material.

20. The composition according to claim 1, wherein the composition further comprises 2-hydroxyethyl methyl cellulose, hydroxypropyl cellulose, ethylcellulose, methylcellulose, methyl ethyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, or any combinations thereof.

Description

[0032] It has to mentioned that the HEC used as a thickening agent—if it is used—has a different function than the HEC which is used as a stabilizer in the binding agent, as described above.

[0033] According to a preferred embodiment of the invention, the composition may comprise at least two fillers, wherein the first filler is a lamellar silicate material and the second further filler is selected from the group consisting of calcium sulfate dihydrate, calcium carbonate, calcium magnesium carbonate and any combination thereof, preferably calcium carbonate, calcium magnesium carbonate and any combination thereof, more preferably calcium magnesium carbonate.

[0034] Preferably, the composition comprises 60 to 65% by weight of the total composition of this second filler.

[0035] According to another preferred embodiment of the invention, the composition may comprise at least a third filler, wherein the third filler is a mica mineral, preferably muscovite.

[0036] According to yet another further preferred embodiment of the invention, the composition further may comprise biocides as additives.

[0037] The biocides may be added to the composition on a basis of 2-methyl-1,2H-thiazol-3(2H)-one (MIT), 1,2-benzoisothiazol-3(2H)-one (BIT) and/or 2-bromo-2-nitropopane-1,3-diol (BNPD).

[0038] It is also preferable, if the composition comprises 0.1 to 1% by weight of the total composition, preferably 0.1 to 0.4% by weight of the total composition of biocides.

[0039] According to the present invention, also a pasty fill and finishing material, in particular a physically drying sprayable fill and finishing material, which is made from the above specified composition is provided. The inventive pasty fill and finishing material provides the advantages already described above in connection with its composition.

[0040] Preferably, the specific weight of the pasty fill and finishing material is between 1.0 kg/l and 1.9 kg/l. In particular preferred it is between 1.2 kg/l and 1.7 kg/l.

[0041] The present invention also provides a method for producing a pasty fill and finishing material, in particular also a pasty fill and finishing material as specified above. The method is based on a two-stage process, according to which in a first step, dry components are homogenized, and in a second step, the homogenized dry components are added to aqueous or water-dilutable components.

[0042] The dry components can comprise fillers, lamellar silicate materials, celluloses, and optionally other dry additives and/or dry binding agents.

[0043] The aqueous or water-dilutable components can comprise binding agents, and optionally other liquid additives. By the inventive method, a pasty fill and finishing material having the above described advantages can be provided.

[0044] Preferably, the first and second steps of the two-stage process may be carried out in parallel for more than 80% of the processing time. Thus, the parallel processing saves processing time, and thus renders the method more economical.

[0045] The resulting pasty fill and finishing material generally can be applied by all methods known from the state of the art, e.g. by aid of mechanic tools or by machine processing. The machine processing is preferred.

[0046] Further details and features of the invention are shown in the following examples, which are just for clarification and do not restrict by any means the scope of protection conferred by the claims.

[0047] Table 1 shows a comparison of state of the art samples comprising palygorskite (attapulgite) and EVA which is not stabilized with HEC (but with PVOH) and an embodiment of the invention comprising sepiolite (instead of palygorskite in the state of the art sample) and EVA stabilized with HEC. However, none of the two comparison examples shows high resistance to scratches and bouncing events.

TABLE-US-00001 TABLE 1 Comparison Comparison Example Example Example according to (regular weight) (light weight) the invention Raw material Chemical description of raw material % by weight % by weight % by weight Dolomite carbonate 60-65 40-50 60-65 powder 90 μm Minugel FG palygorskite (attapulgite) 1-2 1-3 0 MicaCelia 125 muscovite mica 0 0 0.5-2.0 Volite 200 H micronised expanded perlite 0 2-5 0 (SMK) Pangel S9 sepiolite 0 0 0.05-0.2  Cellosize QP hydroxyethyl cellulose (HEC) 0.35-0.6  0.35-0.6  0.35-0.6  52000 Walocel MK hydroxypropyl methyl cellulose 0.01-0.4  0.01-0.4  0.01-0.4  25000 PFV (HPMC) Selvol E205 S polyvinylalcohole (PVOH) 0.1-0.5 0 0 Agitan 351 blend of alkoxylated nonionic 0 0.1-0.2 0 compounds, nonionic fatty compounds and hydrophobic silica Vinamul 3171 poly(ethylene-vinyl acetate) (EVA) 1.0-5.0 1.0-5.0 0 dispersion stabilized with PVOH Mowilith LDM poly(ethylene-vinyl acetate) (EVA) 0 0 5-8 1880 dispersion stabilized with HEC Biocides 2-methyl-1,2H-thiazol-3(2H)-one 0.1-0.4 0.1-0.4 0.1-0.4 (MIT) and 1,2-benzoisothiazol-3(2H)- one (BIT) Water water 25-30 30-50 25-30 Total batch 100  100  100 

[0048] In table 2, in which the same raw materials as the in inventive example of table 1 (except for the materials mentioned in table 2) are used, the influence of the combination of sepiolite with HEC stabilized EVA on the hardness of the surface and the sprayability is shown compared to attapulgite and/or PVOH stabilized EVA (Mowilith LDM 1871 PVOH).

[0049] It has to be mentioned that for having a similar sagging (or slipping down) behavior of the pasty fill and finishing material with attapulgite instead of sepiolite, much more attapulgite (for example 1.9% by weight) is necessary. Surprisingly, this was not the case if Sepiolite was used. With Sepiolite only less (or equal) than 0.20% by weight were needed to arrive to a similar sagging (or slipping down) behavior of the pasty fill and finishing material. The sagging behavior is tested by homogenizing a sample and transferring it without bubbles into a syringe. Then the sample is applied evenly on a specific spot on gypsum plasterboard. Then the gypsum plasterboard is positioned in an upright position at room temperature for 24 hours.

[0050] Afterwards the distance from the lowest point of the sample to the starting point is measured. For example, the inventive composition and the comparison example (regular weight) both have in this test a comparable sagging behavior of around 150 mm, although there is a factor of 8 difference in the amount of the lamellar silicate material.

TABLE-US-00002 TABLE 2 Content EVA (wt %, Content Content Taber abraser solid content in attapulgite sepiolite result (weight polymer dispersion) (% by weight) (% by weight) loss in g) Sprayability Combination of EVA 1.2 1.9 — 2.08 not (PVOH stabilized) sprayable with attapulgite Combination of EVA 1.25 — 0.15 1.21 not (PVOH stabilized) sprayable with sepiolite Combination of EVA 3.8 1.9 — 1.13 not (PVOH stabilized) sprayable with attapulgite Combination of EVA 3.8 — 0.15 1.12 not (PVOH stabilized) sprayable with sepiolite Combination of EVA 3.8 1.9 — 0.83 not (HEC stabilized) with sprayable attapulgite Combination of EVA 3.8 — 0.15 0.70 good (HEC stabilized) with sprayable sepiolite

[0051] Abrasion is tested by bringing up the pasty fill and finishing material as prepared according to the composition described above with a thickness of about 2 mm on a defined piece of a gypsum plasterboard. After drying at room temperature until constant weight (usually 3 days) the prepared sample is weighed and placed into an abrasion testing-machine (Taber-Abraser Modell 503) and is rotated 100 times with 60 rotations per minute and sandpaper S 33 and 500 g of check weight. After that, the weight of the prepared sample is checked again and the difference is the abrasion. According to abrasion, the smaller the value (in g) the higher the scratch resistance. This means that the surface of the composition is harder to destroy.

[0052] A pasty sprayable fill and finishing material having a composition according to an embodiment of the present invention provides for a homogeneous substance, which still has comparably low shear stress, and higher shear rates. The pasty sprayable fill and finishing material having a composition according to an embodiment of the present invention further provides at a layer thickness of 1 to 3 mm a homogeneous surface for optionally following decorative coatings and shows high resistance to scratches and bouncing events. The surface is so smooth that sanding is usually not required.

[0053] Further, a pasty sprayable fill and finishing material having a composition according to an embodiment of the present invention, including sepiolite in combination with a HEC stabilized organic polymer, preferably poly(ethylene-vinyl acetate) (EVA), leads to a mechanical strengthening of the coating during the film formation. Moreover, this combination strengthens the hardness of the film without making the surface brittle or fragile. On a stable substrate, the respective surface shows a significant increase of the scratch resistance and the abrasion resistance by a factor of 10 (profile depth difference in the prior art: 470 μm; profile depth difference in example of table 1: 40 μm).