SPRAY-APPLIED DRYING-TYPE JOINT COMPOUND AND ITS USE IN A WALL INSTALLATION METHOD AS WELL AS A METHOD FOR PREPARING A JOINT COMPOUND FOR SPRAY APPLICATION

摘要

Provided are compositions and methods for expeditious wall installation by spray-applying a joint compound comprising a polymeric binder and hollow spheres. The wet drying-type joint compound for spray application is substantially free of setting minerals, bulk filler, clays, starch, mica, Ca(Mg)C03, expanded perlite, gypsum, talc, diatomaceous earth. It has a shrinkage 15 vol% (ASTM C474-05) and a viscosity adjusted to 15,600 - 23,000 cP (ASTM C474-05).The joint compound comprises 3 - 90 wt% of a latex emulsion binder being selected from acrylic acid polymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies; up to 5 wt% of a nonionic surfactant;up to 3 wt % of a humectant; and 5 - 25 wt% of a plurality of hollow spheres. These spheres are composed of self-contained air bound by a solid barrier, have an average isostatic crush strength of 250 psi (ASTM D3102-78) and a density of 0.04 - 1.1 g/cm3. The hollow spheres are selected from the group consisting of lime boro-silicate, polystyrene, ceramic, recycled-glass, expanded glass, and lightweight polyolefin beads, thermoplastic, thermoset, and any combination thereof. This joint compounnd is used in a wall installation method comprising joining two gypsum boards together such that the edges create a seam and spraying the seam with the drying type joint compound until the seam is filled.