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CA-3052196-C - A MOISTURE-CURABLE ADHESIVE COMPOSITION AND A METHOD FOR MOUNTING TILES ON WALL SURFACES

CA3052196CCA 3052196 CCA3052196 CCA 3052196CCA-3052196-C

Abstract

A moisture-curable adhesive composition comprises a polymer component selected from a silane-terminated polyalkylene oxide and/or a polyurethane; a plurality of amino-silane modified wollastonite fibers having an average aspect ratio of from about 1.5:1 to about 12:1 and an average fiber length of from about 6 µm to about 825 µm; at least two fillers, wherein one of said fillers is untreated and a second of said fillers is treated with a modifier selected from the group consisting of a fatty acid derivative, a silane, a titanate, and mixtures thereof wherein at least one of said fillers is irregularly shaped; and a rheology modifier. The composition preferably further comprises a plurality of irregularly-shaped crumb rubber particles having an average particle size of between about 0.5 to 1.5 mm. The composition is useful for adhering tiles to surfaces, especially large format tiles to substantially vertically-extending wall surfaces.

Inventors

  • Todd V. PORTER
  • Chad P. BULEN
  • Serhan OZTEMIZ
  • Liam P. DEVLIN

Assignees

  • BOSTIK, INC.

Dates

Publication Date
20260505
Application Date
20180205
Priority Date
20170206

Claims (17)

  1. What is Claimed: 1. A moisture-curable adhesive composition comprising: a) a polymer component selected from a silane-terminated polyalkylene oxide and/or a polyurethane; 5 10 15 20 25 30 b) a plurality of amino-silane modified wollastonite fibers having an average aspect ratio of from about 1.5:1 to about 12:1 and an average fiber length of from about 6 µm to about 825 µm; c) at least two fillers, wherein one of said fillers is untreated and a second of said fillers is treated with a modifier selected from the group consisting of a fatty acid derivative, a silane, a titanate, and mixtures thereof and wherein one of said fillers has an average particle size of between about 1.5 µm and about 10 µm and a second of said fillers has an average particle size of between about 0.1 µm and about 1.3 µm, wherein at least one of said fillers is irregularly shaped; d) a rheology modifier.
  2. 2. The composition of claim 1, wherein the polymer component is the silane terminated polyalkylene oxide and is present in an amount of about 5 to about 40% by weight.
  3. 3. The composition of claim 2, wherein: the silane-terminated polyalkylene oxide is present in an amount of about 10 to about 30% by weight; the plurality of amino-silane modified wollastonite fibers is present in an amount of about 3 to about 15% by weight, and the amino-silane loading is about 1 to about 35% by weight of the fibers; the at least two fillers are present in an amount of about 30 to about 70% by weight; and the composition further comprises a plasticizer in an amount of about 2 to about 40% by weight. 41 1389-7507-5342.1
  4. 4. The composition of claim 3, wherein: the silane-terminated polyalkylene oxide is present in an amount of about 12 to about 24% by weight; 5 10 15 20 25 30 the plurality of amino-silane modified wollastonite fibers is present in an amount of about 5 to about 10% by weight, and the amino-silane loading is about 2 to about 20% by weight of the fibers; the at least two fillers are present in an amount of about 40 to about 60% by weight; and the plasticizer is present in an amount of about 10 to about 30% by weight.
  5. 5. The composition of claim 4, wherein: the silane-terminated polyalkylene oxide is present in an amount of about 15 to about 20% by weight; the plurality of amino-silane modified wollastonite fibers is present in an amount of about 6 to about 8% by weight, and the amino-silane loading is about 4 to about 10% by weight of the fibers; the at least two fillers are present in an amount of about 42 to about 50% by weight; and the plasticizer is present in an amount of about 18 to about 24% by weight.
  6. 6. The composition of claim 1 further comprising a plurality of irregularly-shaped crumb rubber particles having an average particle size of between about 0.5 to 1.5 mm.
  7. 7. The composition of claim 6, wherein the plurality of irregularly-shaped crumb rubber particles is present in an amount of about 0.5 to about 10% by weight.
  8. 8. The composition of claim 1 further comprising a dehydrating agent, an adhesion promoter, and a catalyst. 42 1389-7507-5342.1
  9. 9. The composition of claim 1, wherein the silane-terminated polyalkylene oxide comprises: 5 10 15 20 25 30 a first silane-terminated polyalkylene oxide comprising a methoxysilyl chain polymer and having a branched polyether backbone and a molecular weight in the range of about 16,000 to about 18,000 g/mol; and a second silane-terminated polyalkylene oxide comprising a methoxysilyl chain polymer and having a linear polyether backbone and a molecular weight in the range of about 26,000 to about 28,000 g/mol.
  10. 10. The composition of claim 9, wherein: the first silane-terminated polyalkylene oxide is present in an amount of between about 5 to about 30% by weight; and the second silane-terminated polyalkylene oxide is present in an amount of between about 0.5 to about 5% by weight.
  11. 11. The composition of claim 1, wherein the at least two fillers comprise: a first filler comprising stearate-treated ground calcium carbonate particles and having a mean particle size between about 1.5 µm and about 10 µm, wherein said first filler is present in the composition in an amount of about 1 to about 27% by weight; a second filler comprising untreated ground calcium carbonate particles and having a mean particle size between about 1.5 µm and about 10 µm, wherein said second filler is present in the composition in an amount of about 1 to about 34% by weight; and a third filler comprising stearate-treated ground calcium carbonate particles and having a mean particle size between about 0.1 µm and about 1.3 µm, wherein said third filler is present in the composition in an amount of about 1 to about 20% by weight.
  12. 12. The composition of claim 1, wherein the average aspect ratio of the plurality of the amino-silane modified wollastonite fibers is from about 2:1 to about 8:1 and 43 1389-7507-5342.1 the average fiber length of the amino-silane modified wollastonite fibers is from about 10 µm to about 40 µm. 5 10 15 20
  13. 13. The composition of claim 12, wherein the average aspect ratio of the plurality of the amino-silane modified wollastonite fibers is from about 2:1 to about 5:1 and the average fiber length of the amino-silane modified wollastonite fibers is from about 12 µm to about 25 µm.
  14. 14. The composition of claim 1, wherein the untreated filler has an average particle size of about 3 µm and the treated filler has an average particle size of about 0.7 µm.
  15. 15. The composition of claim 1, wherein the modifier is the fatty acid derivative.
  16. 16. The composition of claim 1, wherein the fatty acid derivative comprises stearic acid.
  17. 17. The composition of claim 1, wherein the polymer component is the polyurethane and the polyurethane comprises a silane-modified polyurethane. 44 1389-7507-5342.1

Description

WO 2018/145002 PCT /US2018/016862 A MOISTURE-CURABLE ADHESIVE CONIPOSITION AND A METHOD FOR MOUNTING TILES ON WALL SURF ACES CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit under 35 US.C. § 119 of U.S. patent application numbers 62/455, 142, filed Febmary 6, 2017, and 62/470,524, filed March 13, 2017. FIELD OF THE INVENTION This invention relates to adhesive compositions and methods for adhering 10 together adherends, especially for mounting tiles on wall surfaces More particularly, the adhesive composition is suitable for mounting large format tiles including gauged porcelain panels on wall surfaces. BACKGROUND OF THE INVENTION A number of properties must be balanced when developing an adhesive 15 formulation used to mount tiles to surfaces, such as flooring, sub-flooring, or wall swfaces For example, the adhesive composition must have a long enough open time so that it can be applied to the back surface of the tile and/or the mounting surface, as needed, and yet must cure relatively quickly after the tile is put in place while still allowing for some small level of adjustment by repositioning after mounting the tile on 20 the surface The uncured adhesive also should have desirable rheological properties such that it can be mixed and applied easily yet resists the shear imposed by gravity. Such considerations are especially challenging when the adhesive composition is used to mount tiles to wall surfaces and even more so when those tiles are large or have a high area density (i e, weight of the tile per surface area of the tile). In such instances, the 25 adhesive must demonstrate good sag resistance (also known as green grab) In addition, it is desirable that the formulation minimizes the formation of "legs" or strings of material that come off the trowel after application and potentially drip down the wall surface Finally, the adhesive formulation preferably minimizes or eliminates the formation of void spaces between the tile and the mounting surface A recent trend in tile manufacturing and installation is the use oflarge format tiles. As used herein, a large format tile means any tile having a surface area of at least 5 one square meter For example, the dimensions of a large format tile may be 1 x 1 meters, I x3 meters, 1 5x4.5 meters, and other dimensions One type of large format tiles is gauged porcelain tiles, which are thin (e.g., about 3 - 6.5 mm thick) porcelain tiles that are at least one square meter In view of the surface area and relative thinness of these tiles, breakage of the tiles upon installation is a concern. Furthennore, the current IO guidelines of the Tile Council of North America (TCNA) specify a lippage, which is the variation in height of adjoining tiles, for gauged porcelain tiles of no more than onesixteenth of an inch. Mounting of large format tiles in general, and specifically of gauged porcelain tiles, has proven dit1icult with breakage being a significant problem, resulting in financial loss and delays. An impact to the side or edge of such tiles may cause it to 15 chip or break. The current method of mounting large format tiles on walls or vertical surfaces with a traditional ceramic tile adhesive, as recommended by installation guides by the tile manufacturer, uses inorganic binders that are largely mortar based and have a number of downsides to the process, as follows l. 2 The current process is a messy process of mixing, applying, and disposing of the mmtar The mixing of the mortar with water creates a large amount of dust at the job site, which raises both health and safety issues and leads to extra man hours to clean the area. The mixing itself also requires the use of power tools, which necessitates the proximity to working near electrical outlets or po1table power generators. 3 If any material is forced out into the grout lines, the cured material is very difficult to remove without damaging the tile 2 WO 2018/U5002 PCT/US2018/016862 4. The current binder, once mixed, has a short pot life that cannot be retarded once mixed. This leads to excessive waste as the installer must accurately measure the amount needed as it is not possible to save mixed material which is not used during the pot life 5. The current method also requires a significant amount oflabor during application due to the need to "back butter" the tiles. This step requires the installer to place adhesive/mortar on the mounting surface ( or substrate, such as a wall surface) as well as the back surface of the tile before application. The tile is then placed on the substrate that has been coated in adhesive/mortar. Once applied, it is common practice to use a vibratory power tool to remove all the air pockets behind the tile to ensure adequate coverage/support and minimize voids. 6 The current method cannot form chemical bonds with the current tile. The backing is largely an epoxy/fiberglass composite that will not chemically bond with the current mortars. This leads to a poss