Coating and binder compositions for gypsum boards
AssigneesAxalta Coating Systems IP Co., LLC, Georgia-Pacific Gypsum LLC
InventorsMichael D. Foster, Nellie Moretz, James E. Bailey, John E. Kirkwood, Brian W. Bland, Ali Fadhel
Life of this patent
Estimating the term…
Abstract
An adhesive binder composition for adhering a paper sheet to a gypsum article with a gypsum layer having at least one paper sheet on a major surface thereof. The adhesive binder composition includes a polymeric adhesive and at least one surfactant. The adhesive binder composition resides at a boundary between the gypsum layer and the paper sheet.
Claims15
An adhesive binder composition for adhering a paper sheet to a gypsum article comprising a gypsum layer having at least one paper sheet on a major surface thereof, wherein the gypsum layer comprises a low density core layer having a high density slate layer on at least one major surface thereof adjacent the paper sheet, the adhesive binder composition comprising:
- about 90% by weight to about 30% by weight, based on the total weight of non-volatile components in the adhesive binder composition, of a polymeric adhesive, wherein the polymeric adhesive comprises an aqueous emulsion chosen from acrylics, styrene acrylics, vinyl acrylics, styrene acetate acrylics, and combinations thereof, wherein the polymeric adhesive provides an extended liquid phase open time and the open time is controlled so that gypsum particle crystallization is not impeded, and wherein the polymeric adhesive comprises a polymer or a copolymer with a glass transition temperature of 0 to 30° C., and
- at least one surfactant, and
- wherein the slate layer comprises about 4% by weight to about 40% by weight of the adhesive binder composition.
A wallboard article, comprising:
- a gypsum layer having a gypsum core layer and at least one high density gypsum slate layer adjacent the core layer, wherein the gypsum layer comprises a low density core layer having a high density gypsum slate layer on each major surface thereof;
- and
- a paper sheet on each major surface of the high density gypsum slate layer, wherein the paper sheet is adhered to the high density gypsum slate layer, wherein the high density gypsum slate layer comprises about 4% by weight to about 40% by weight of an adhesive binder composition comprising a polymeric adhesive and at least one surfactant and has a humid bond strength with the paper sheet of at least 3 N-m, the adhesive binder composition comprising about 90% by weight to about 30% by weight, based on the total weight of non-volatile components in the adhesive binder composition, of the polymeric adhesive, wherein the polymeric adhesive provides an extended liquid phase open time and the open time is controlled so that gypsum particle crystallization is not impeded, wherein the polymeric adhesive comprises an aqueous emulsion chosen from acrylics, styrene acrylics, vinyl acrylics, styrene acetate acrylics, and combinations thereof, and wherein the polymeric adhesive comprises a polymer or a copolymer with a glass transition temperature of 0 to 30° C.
A wallboard article, comprising:
- a gypsum layer having a gypsum core layer and at least one high density gypsum slate layer adjacent the core layer, wherein the high density gypsum slate layer comprises about 4% by weight to about 40% by weight of an adhesive binder composition, comprising:
- about 90% by weight to about 30% by weight, based on the total weight of non-volatile components in the adhesive binder composition, of a polymeric adhesive, the polymeric adhesive comprising an aqueous emulsion chosen from acrylics, styrene acrylics, vinyl acrylics, styrene acetate acrylics, and combinations thereof, wherein the polymeric adhesive provides an extended liquid phase open time and the open time is controlled so that gypsum particle crystallization is not impeded, and wherein the polymeric adhesive comprises a polymer or a copolymer with a glass transition temperature of 0 to 30° C., and
- at least one surfactant;
- and
- a paper sheet on the high density gypsum slate layer, wherein the paper sheet is adhered to the high density gypsum slate layer with a humid bond strength of at least 3 N-m.
Dependencies are inferred from the claim text.