Lightweight joint compound containing stable air pockets
View Patent ↗Low density joint compounds, and methods for their use are disclosed. Joint compounds comprising water, calcium carbonate, a foaming agent, and a rheology modification agent contain a plurality of stable air bubbles. Joint compounds can have densities of about 4 pounds per gallon to about 8 pounds per gallon. A presently prepared composition has a density of about 4.8 pounds per gallon. A presently preferred foaming agent is a polyether siloxane copolymer. A presently preferred rheology modification agent is poly(ethylene oxide). The joint compounds can comprise additional components such as perlite, mica, talc, preservatives, and latex.
1. A joint compound composition comprising water, calcium carbonate, a foaming agent, and a rheology modification agent, wherein:
the composition comprises a plurality of stable air bubbles;
the concentration of foaming agent in the composition is about 0.01 weight percent to about 10 weight percent; and
the composition has a density of about 4 pounds per gallon to about 8 pounds per gallon.
2. The composition of claim 1 , wherein the foaming agent is a polyether siloxane copolymer.
3. The composition of claim 1 , wherein the rheology modification agent is poly(ethylene oxide).
4. The composition of claim 1 , wherein the concentration of water in the composition is about 20 weight percent to about 55 weight percent.
5. The composition of claim 1 , wherein the concentration of calcium carbonate in the composition is about 10 weight percent to about 50 weight percent.
6. The composition of claim 1 , wherein the concentration of rheology modification agent in the composition is about 0.01 weight percent to about 10 weight percent.
7. The composition of claim 1 , further comprising perlite.
8. The composition of claim 7 , wherein the concentration of perlite in the composition is about 2 weight percent to about 40 weight percent.
9. The composition of claim 1 , further comprising mica.
10. The composition of claim 9 , wherein the concentration of mica in the composition is about 0.5 weight percent to about 10 weight percent.
11. The composition of claim 1 , further comprising talc.
12. The composition of claim 11 , wherein the concentration of talc in the composition is about 0.5 weight percent to about 10 weight percent.
13. The composition of claim 1 , further comprising a preservative.
14. The composition of claim 13 , wherein the concentration of preservative in the composition is about 0.02 weight percent to about 1 weight percent.
15. The composition of claim 1 , further comprising latex emulsion.
16. The composition of claim 15 , wherein the concentration of latex emulsion in the composition is about 0.5 weight percent to about 5 weight percent.
17. The composition of claim 1 , further comprising a latex powder.
18. The composition of claim 17 , wherein the concentration of latex powder in the composition is about 0.5 weight percent to about 5 weight percent.
19. A joint compound comprising
water, calcium carbonate, a foaming agent, and a rheology modification agent, wherein:
the composition comprises a plurality of stable air bubbles;
the composition has a density of about 4 pounds per gallon to about 8 pounds per gallon; and
the composition is stable at 70° F. for at least about six months.
20. The composition of claim 1 , wherein the composition has a density of about 4.8 pounds per gallon.
21. A joint compound composition comprising:
about 20 weight percent to about 55 weight percent water;
about 10 weight percent to about 50 weight percent calcium carbonate;
about 0.01 weight percent to about 10 weight percent foaming agent; and
about 0.01 weight percent to about 10 weight percent rheology modification agent;
wherein the composition has a density of about 4 pounds per gallon to about 8 pounds per gallon.
22. The composition of claim 21 , wherein the foaming agent is a polyether siloxane copolymer.
23. The composition of claim 21 , wherein the rheology modification agent is poly(ethylene oxide).
24. A joint compound composition comprising:
about 45 weight percent water;
about 29 weight percent calcium carbonate;
about 0.06 weight percent polyether siloxane copolymer; and
about 0.11 weight percent poly(ethylene oxide).
25. A joint compound composition comprising:
about 20 weight percent to about 55 weight percent water;
about 10 weight percent to about 50 weight percent calcium carbonate;
about 0.01 weight percent to about 10 weight percent polyether siloxane copolymer;
about 0.5 weight percent to about 10 weight percent mica;
about 0.5 weight percent to about 10 weight percent talc;
about 2.0 weight percent to about 40 weight percent perlite;
about 0.01 weight percent to about 10 weight percent poly(ethylene oxide);
about 0.5 weight percent to about 5 weight percent latex emulsion;
about 0.5 weight percent to about 5 weight percent latex powder; and
about 0.1 weight percent to about 8 weight percent cellulose ether.
26. The composition of claim 25 , having a density of about 4 pounds per gallon to about 8 pounds per gallon.
27. The composition of claim 25 , having a density of about 4.8 pounds per gallon.
28. A joint compound consisting essentially of:
about 45.2 weight percent water;
about 0.16 weight percent preservatives;
about 29.0 weight percent calcium carbonate;
about 4.52 weight percent mica;
about 4.52 weight percent talc;
about 9.49 weight percent perlite;
about 0.11 weight percent poly(ethylene oxide);
about 0.06 weight percent polyether siloxane copolymer;
about 3.01 weight percent latex emulsion;
about 1.13 weight percent latex powder; and
about 0.9 weight percent cellulose ether.
29. The composition of claim 28 , having a density of about 4 pounds per gallon to about 8 pounds per gallon.
30. The composition of claim 28 , having a density of about 4.8 pounds per gallon.