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US 2010/0062264 A1Published application
Polymer emulsion coating or binding formulations and methods of making and using same
AssigneeBASF SE
InventorsPeter C. Hayes, Ronald Horwitz
Life of this patent
Estimating the term…
Abstract
Polymer emulsion formulations suitable for use as binders or in coating systems generally are provided. The formulations comprise a copolymer derived from one or more vinyl ester monomers of the formula I, one or more copolymerizable surfactants of formula II, and optionally one or more additional co-monomers. Gypsum boards, methods of making gypsum boards, and methods of making the copolymer are also disclosed.
Claims25
A polymer emulsion, comprising a copolymer derived from:
- at least one vinyl ester of formula I:
- CH2═CR1—O—CO—R2, (I)
- wherein R1 is H or CH3 and R2 is C6-C12 branched or straight chain alkyl at least one copolymerizable surfactant of formula II, or salt thereof:
- wherein R1 represents a branched aliphatic hydrocarbon group, a secondary aliphatic hydrocarbon group or a branched aliphatic acyl group, AO and AO′ each independently represents an oxyalkylene group having 2 to 4 carbon atoms, R2 and R3 each independently represents a hydrogen atom or a methyl group, x stands for a number of from 0 to 12, y stands for a number of 0 to 1, z stands for a number of from 1 to 10, X represents a hydrogen atom or an ionic hydrophilic group, m stands for a number of from 0 to 1,000, and n stands for a number of from 0 to 1,000;
- and
- optionally one or more additional co-monomers.
3 more elements
A gypsum board, comprising:
- a gypsum core;
- a first glass scrim positioned on one side of the gypsum core;
- a second glass scrim positioned on an opposite side of the gypsum core;
- wherein at least one of the first glass scrim and the second glass scrim has a surface at least partially coated with a coating formulation comprising a copolymer derived from:
- at least one vinyl ester of formula I:
- CH2═CR1—O—CO—R2, (I)
- wherein R1 is H or CH3 and R2 is C6-C12 branched or straight chain alkyl at least one copolymerizable surfactant of formula II, or salt thereof:
- wherein R1 represents a branched aliphatic hydrocarbon group, a secondary aliphatic hydrocarbon group or a branched aliphatic acyl group, AO and AO′ each independently represents an oxyalkylene group having 2 to 4 carbon atoms, R2 and R3 each independently represents a hydrogen atom or a methyl group, x stands for a number of from 0 to 12, y stands for a number of 0 to 1, z stands for a number of from 1 to 10, X represents a hydrogen atom or an ionic hydrophilic group, m stands for a number of from 0 to 1,000, and n stands for a number of from 0 to 1,000;
- and
- optionally one or more additional co-monomers.
7 more elements
A method of making a gypsum board, comprising:
- coating at least a portion of a surface of a glass scrim with a polymer emulsion comprising a copolymer derived from
- at least one vinyl ester of formula I:
- CH2═CR1—O—CO—R2, (I)
- wherein R1 is H or CH3 and R2 is C6-C12 branched or straight chain alkyl
- at least one copolymerizable surfactant of formula II, or salt thereof:
- wherein R1 represents a branched aliphatic hydrocarbon group, a secondary aliphatic hydrocarbon group or a branched aliphatic acyl group, AO and AO′ each independently represents an oxyalkylene group having 2 to 4 carbon atoms, R2 and R3 each independently represents a hydrogen atom or a methyl group, x stands for a number of from 0 to 12, y stands for a number of 0 to 1, z stands for a number of from 1 to 10, X represents a hydrogen atom or an ionic hydrophilic group, m stands for a number of from 0 to 1,000, and n stands for a number of from 0 to 1,000;
- and
- optionally one or more additional co-monomers.
- laying the glass scrim on wet gypsum to attach the glass scrim to the gypsum to form a glass-gypsum composite;
- and
- drying the glass-gypsum composite or allowing the glass-gypsum composite to dry.
8 more elements
A method of making a copolymer, comprising reacting:
- at least one vinyl ester of formula I:
- CH2═CR1—O—CO—R2, (I)
- wherein R1 is H or CH3 and R2 is C6-C12 branched or straight chain alkyl
- at least one copolymerizable surfactant of formula II, or salt thereof:
- wherein R1 represents a branched aliphatic hydrocarbon group, a secondary aliphatic hydrocarbon group or a branched aliphatic acyl group, AO and AO′ each independently represents an oxyalkylene group having 2 to 4 carbon atoms, R2 and R3 each independently represents a hydrogen atom or a methyl group, x stands for a number of from 0 to 12, y stands for a number of 0 to 1, z stands for a number of from 1 to 10, X represents a hydrogen atom or an ionic hydrophilic group, m stands for a number of from 0 to 1,000, and n stands for a number of from 0 to 1,000;
- and
- optionally one or more additional co-monomers.
4 more elements
Dependencies are inferred from the claim text.