Wall compounds and methods of use
A wall compound for use in all applications and particularly well-suited for joining adjacent wallboards. The compound includes a latex resin, a thickener, fibers, and a filler material. In some embodiments, the repair compound is configured to exhibit at least one of yield stress and pseudoplastic-type behavior. In some embodiments, the compound includes hydrophobic and hydrophilic fibers of different morphologies. In some embodiments, the wall compound includes one or more associative thickeners.
1. A wall compound comprising:
a latex resin or resin binder present in an amount of about 50% by weight or less, based on the total weight of the compound;
a thickener package including a hydrophilic alkali swellable emulsion, wherein the thickener package is present in amount of 1% by weight or less, based on the total weight of the compound;
hydrophobic dry fibrillated fibers and hydrophilic fibers; and
a filler material consisting of substantially spherical synthetic inorganic filler, wherein the wall compound exhibits yield stress behavior, having a yield stress value of at least 200 and no greater than 1000 Pa, and wherein the compound exhibits a Viscosity at 1500 Pa of stress of no greater than 10 Pa·s, each as measured according to the description.
2. The wall compound of claim 1 , wherein the latex resin or resin binder is at least one of a vinyl acrylic polymer or copolymer, an acrylic polymer or copolymer, an acrylate polymer or copolymer, a polyvinyl acetate polymer or copolymer, an ethylene vinyl acetate polymer or copolymer, a styrene-butadiene polymer or copolymer, a polyacrylamide polymer or copolymer, a natural rubber latex, a natural starch, a synthetic starch, and casein.
3. The wall compound of claim 1 , wherein the latex resin or resin binder is 100% acrylate.
4. The wall compound of claim 1 , wherein the compound exhibits a Viscosity at 1500 Pa of stress of no greater than 9 Pa·s.
5. The wall compound of claim 1 , wherein the thickener package includes a polyurethane based rheology modifier.
6. The wall compound of claim 1 , The wall compound of any of the preceding claims, wherein the fibers are present in total in an amount of no greater than 3% by weight, based on the total weight of the compound.
7. The wall compound of claim 1 , wherein the hydrophobic dry fibrillated fibers have a length and the hydrophilic fibers have a length and the length of the hydrophobic dry fibrillated fibers is less than the length of the hydrophobic fibers.
8. The wall compound of claim 7 , wherein the fibers include hydrophobic dry fibrillated polyethylene fibers and hydrophilic rayon fibers.
9. The wall compound of claim 1 wherein the filler is at least one of glass bubbles and ceramic microspheres.
10. The wall compound of claim 1 , further comprising at least one of an adhesion promoter, a humectant, a surfactant, a dispersing agent, an activator, a pH control agent, a colorant, a primer, a smoothing agent, water, and a preservative.
11. The wall compound of claim 1 , further comprising titanium dioxide present in an amount of between about 5% by weight and about 20% by weight.
12. The wall compound of claim 1 , wherein the thickener includes an HEUR and the alkali swellable emulsion.
13. The wall compound of claim 1 , wherein the wall compound is a yield stress fluid and has a density of not greater than 6 lbs/gal.
14. A method for affixing and holding two panels together at a joint seam, the method comprising: creating a joint seam by positioning two panels such that the panels abut; and applying the wall compound of claim 1 to the joint seam and some panel surface area around the seam.
15. The method of claim 14 , wherein the wall compound is allowed to dry and create a film, and wherein the method further comprises applying at least one coat of a wall compound over at least a portion of the film.
16. The method of claim 14 , wherein the method is performed without joint reinforcement tape.
17. A wall compound comprising:
a latex resin or resin binder; present in an amount of about 50% by weight or less, based on the total weight of the compound;
a thickener package comprising a rheology modifier and a hydrophilic alkali swellable emulsion;
two or more types of fibers; and
glass bubbles, wherein the wall compound exhibits yield stress behavior, having a yield stress value of at least 200 and no greater than 1000 Pa, and wherein the compound exhibits a Viscosity at 1500 Pa of stress of no greater than 10 Pa·s, each as measured according to the description.
18. The wall compound of claim 17 , wherein the fibers include hydrophobic dry fibrillated polyethylene fibers and hydrophilic rayon fibers.