A composite board comprising inorganic and/or cellulosic materials and a latex composition as a binder, said composite board having dimensional stability and strength

0001This invention relates to composite boards containing inorganic and cellulosic materials, and comprising a latex composition as a binder.

0002Starch is well known in the art as a binder for composite boards such as ceiling tile. However, under certain environmental conditions, like increased temperature and humidity, the boards lose dimensional stability, e.g., ceiling tile with starch binder sags. At the same time, the board is also required to have adequate strength, e.g., good modulus of rupture, to withstand normal handling and use.

0003Accordingly, it would be desirable to develop a binder composition to serve as a partial or complete replacement for starch which produces a composite board having adequate strength and dimensional stability with increased temperature and humidity.

0004EP-A 0 178 612 corresponding to DE-A-3 438 388, describes a composite board comprising a binder having a Tg (glass transition temperature) of between 60 and 110°C, salts of polyvalent metals and C₁₂-C₃₆ carboxylic acids; and mineral fibers. Said carboxylic acid salts are not required or used in the composition board of the present invention to obtain the desired physical characteristics.

0005EP-A 0 123 234 corresponding to DE-A-3 314 373, describes a composite board comprising a binder having a Tg of between 30 and 80°C and mineral fibers.

0006Both prior art documents teach the use of a binder comprising 60-100 weight percent of (meth)acrylates having 1-4 carbon atoms in the alcoholic group and 0-40 weight percent of (meth)acrylonitrile and/or styrene. According to the present invention, the presence of at least 60 percent (meth)acrylates in the binder appears to be not essential at all. Contrary to the teaching of both EP-A's cited, composition boards having the desirable characteristics aimed at according to the present invention are hereinbelow disclosed, wherein (meth)acrylates are absent or are present in low percentages by weight.

0007A similar copolymer is described in DE-A-3 603 433 wherein it is used together with 5-30 wt.% cement in construction boards.

0008EP-A 0 115 704 relates to a latex composition comprising an aqueous dispersion of 80-95 percent by weight of styrene, and 5-20 percent by weight of a butadiene. The copolymer particles have a Tg of between 45 and 65°C. The latex compositions described are used as toner resins.

0009In EP-A 0 044 399 a specific copolymer is described, essentially consisting of: <ul id="ul0001" list-style="none" compact="compact"><li>31-64 weight percent of at least one vinyl aromatic unit;</li><li>24-65 weight percent of at least one ester of an α,β-ethylenically unsaturated, 3-5 carbon atoms containing mono- or dicarboxylic acid with a C₁-C₁₄ monoalcohol, which ester is free of carboxylic acid groups;</li><li>4-30 weight percent of at least one carboxylic groups containing α,β-ethylenically unsaturated compound having 3-14 carbon atoms; and</li><li>0-5 weight percent of other α,β-ethylenically unsaturated compounds. The copolymer is further defined by a number of parameters. This prior art copolymer composition may be used as a paint or impregnating agent. Thereto, the copolymer is solubilised in an organic solvent and neutralized with ammonia.</li></ul>

0010Finally, DE-OS 35 06 710 describes a copolymer latex composition for use in a paper coating mass. In the first paragraph of page 9 of this DE-OS it is mentioned that the copolymer latex itself is a binder for paper. For this purpose, it is necessary that the copolymer latex is in the form of heterogeneous particles, which are obtained by graft polymerisation.

0011The present invention relates to a composition board as defined in claim 1.

0012The resulting composite board has sufficient strength for necessary handling and use and maintains dimensional stability with increased temperature and humidity.

0013In addition, the present invention relates to a process for preparing the composite board of the invention as defined in claim 4.

0014What is meant by "dimensional stability" is a lack of movement of the composite board when exposed to increased temperature and humidity. Dimensional stability can be measured by evaluating sag resistance of the composite board. Sag resistance is determined by exposing a 1 <maths id="math0001"><math display="inline"><mrow><mfrac><mrow><mtext>1</mtext></mrow><mrow><mtext>2</mtext></mrow></mfrac></mrow></math><img file="EP0266850B2_D0001.tif" /></maths> x 6-inch (40 mm x 150 mm) strip of composite board of the composition described in Example 1 to 94°F (35°C), 90 percent relative humidity for 96 hours, holding 330 g of weight and then measuring the displacement of the center of the board in millimeters (mm). The composite board will sag less than 0.8 mm and, preferably, less than 0.5 mm.

0015What is meant by "strength" is that the resulting composite board of the composition has the integrity necessary to withstand handling, processing and other forces that are applied to the composite board. The necessary strength can be determined by measuring the modular of rupture (MOR) of the composition board by ASTM 367-78. Preferably, the composite board has a modulus of rupture (MOR) of at least 130 psi (0.90 MPa). More preferably, the composite board has an MOR of at least 140 psi (0.96 MPa). The most preferred MOR is at least 150 psi (1.0 MPa).

0016MOR is calculated from the standard 3 point breaking loading test described in ASTM 367-78 as follows: Modulus of Rupture (MOR) = 3 PL/bd²    where: <dl id="dl0001" compact="compact"><dt>P =</dt><dd>peak force required to break the sample (lb)</dd><dt>L =</dt><dd>span between the sample supports (in)</dd><dt>b =</dt><dd>width of the sample (in)</dd><dt>d =</dt><dd>thickness of the sample.</dd></dl>

0017This modulus of rupture is corrected for density variation as shown: MOR corrected = (MOR) D²    where D is the density correction D = desired density/actual density

0018The glass transition temperature (T_g) of the copolymer of latex of the present invention is defined functionally as that T_g which is sufficient to maintain the dimensional stability of the resulting composite board when it is exposed to specific environmental conditions and to provide the resulting composite board with a modulus of rupture of at least 130 psi (0.90 MPa) as measured by ASTM 367-78. The T_g of the latex polymer is from 50°C to 115°C, preferably from 50°C to 110°C.

0019The latex copolymer composition to be used in the present invention can be prepared by a conventional emulsion polymerization process in aqueous medium with conventional additives. Typically, the aqueous phase will contain from 0.5 to 5 weight percent (based on the monomer charge) of conventional nonionic or anionic emulsifiers (e.g., potassium N-dodecyl sulfonate, sodium isooctobenzene sulfonate, sodium laurate and nonyl phenol ethers of polyethylene glycols).

0020Conventional emulsion polymerization catalysts can be employed in the foregoing latex polymerization and common examples thereof include peroxides, such as hydrogen peroxide; persulfates, such as sodium persulfate, potassium persulfate and ammonium persulfate; and azo compounds, such as azodiisobutyric diamide. Catalysts (e.g.. redox catalysts) which are activated in the water phase (e.g., by a water-soluble reducing agent) can be employed also. The type and amount of catalyst, as well as the particular polymerization conditions employed, will typically depend on the other monomers which are used and polymerization conditions will be generally selected to favor the polymerization of such other monomers. Typically, such catalysts are employed in a catalytic amount, e.g., ranging from 0.01 to 5 weight percent based upon the monomer weight. In general, the polymerization is conducted at a temperature in the range of from -10° to 110°C, preferably from 50° to 90°C.

0021Similarly, conventional chain transfer agents such as, for example, n-dodecyl mercaptan, bromoform, and carbon tetrachloride can also be employed in the normal fashion in polymerization to regulate the molecular weight of the polymer formed therein and, typically, when such chain transfer agents are used, they are employed in amounts ranging from 0.01 to 10, preferably from 0.1 to 5 weight percent based upon the weight of the monomers employed in the polymerization. The amount of chain transfer agent employed depends somewhat on the particular transfer agent employed and the particular monomers being polymerized.

0022Similarly, conventional cross-linking agents, which can be a di-, tn- or tetra-vinyl compound, can also be employed in the normal fashion in polymerization to regulate the T_g and the molecular weight of the polymer formed therein. Representative examples of cross-linking agents are divinylbenzene, allyl methacrylate or a mono-, di-, tri- or tetraethylene glycol diacrylate or dimethacrylate. Typically, when such cross-linking agents are used, they are employed in amounts ranging from 0.01 to 4.0, preferably from 0.1 to 1.0 weight percent based upon the weight of the monomers employed in the polymerization. The amount of cross-linking agent employed depends on the monomers being polymerized.

0023The latex composition used as a binder in the composite board of the present invention with a sufficient T_g is prepared with a combination of hard monomer and soft monomer. An α,β-ethylenically unsaturated carboxylic acid is also incorporated.

0024The term "hard monomer" is meant to include a monomer whose homopolymer has a T_g of at least 80°C and the term "soft monomer" is meant to include a monomer whose homopolymer has a T_g less than 35°C. Typical hard monomers are those conventionally known in the art, for example styrene and methyl methacrylate. Soft monomers are also conventionally known in the art and include, for example, butadiene, ethyl acrylate or butyl acrylate.

0025The α,β-ethylenically unsaturated carboxylic acids include compositions of the formula: <chemistry id="chem0001" num="0001"><img file="EP0266850B2_D0002.tif" /></chemistry> where <ul id="ul0002" list-style="none" compact="compact"><li>R is H and R' is H, C₁-C₄ alkyl, or -CH₂COOX;</li><li>R is -COOX and R' is H or -CH₂COOX; or,</li><li>R is CH₃ and R' is H; and</li><li>X is H or C₁-C₄ alkyl.</li></ul>

0026Suitable α,β-ethylenically unsaturated aliphatic carboxylic acids are monoethylenically unsaturated monocarboxylic, dicarboxylic and tricarboxylic acids having the ethylenic unsaturation α,β to at least one of the carboxyl groups and similar monomers having a higher number of carboxyl groups. It is understood that the carboxyl groups may be present in the acid or salt form (-COOM in which M represents hydrogen or a metal, such as for example, sodium or potassium) and are readily interconvertible by well known simple procedures.

0027Specific examples of the α,β-ethylenically unsaturated aliphatic carboxylic acids are acrylic acid, methacrylic acid, fumaric acid, itaconic acid, maleic acid, aconitic acid, various α-substituted acrylic acids sucn as α-ethacrylic acid, α-propyl acrylic acid and α-butyl acrylic acid.

0028The latex composition typically includes from 50 to 99 weight percent of a hard monomer and from 1 to 50 weight percent of a soft monomer, based on the weight of the composition. The carboxylic acid level may be from 0 to 20 weight percent. Preferably, the hard monomer is present in an amount of from 65 to 95 weight percent, the soft monomer is present in an amount of from 5 to 35 weight percent and the carboxylic acid is present in an amount more preferably of from 0.5 to 10 weight percent, all based on the weight of the composition.

0029A particular copolymer family suitable for the latex of the present invention is a copolymer comprising a monovinylidene monomer, an aliphatic conjugated diene, and an α,β-ethylenically unsaturated carboxylic acid termonomer.

0030The term "monovinylidene monomer" is intended to include those monomers wherein a radical of the formula: <chemistry id="chem0002" num="0002"><img file="EP0266850B2_D0003.tif" /></chemistry> (wherein R is hydrogen or a lower alkyl such as an alkyl having from 1 to 4 carbon atoms) is attached directly to an aromatic nucleus containing from 6 to 10 carbon atoms, including those wherein the aromatic nucleus is substituted with alkyl or halogen substituents. Typical of these monomers are styrene, α-methylstyrene, ortho-, meta- and para-methylstyrene; ortho-, meta- and paraethylstyrene; o,p-dimethylstyrene; o,p-diethylstyrene; isopropylstyrene; o-methyl-p-isopropylstyrene; p-chlorostyrene; p-bromostyrene; o,p-dichlorostyrene; o,p-dibromostyrene; vinylnaphthalene; diverse vinyl (alkylnaphthalenes) and vinyl (halonaphthalenes) and comonomeric mixtures thereof.

0031Acyclic aliphatic conjugated dienes usefully employed herein include typically those compounds which have from 4 to 9 carbon atoms, for example, 1,3-butadiene, 2-methyl-1,3-butadiene; 2,3-dimethyl-1,3-butadiene; pentadiene; 2-neopentyl-1,3-butadiene and other hydrocarbon analogs of 2,3-butadienes, such as 2-chloro-1,3-butadiene; 2-cyano-1,3-butadiene, the substituted straight chain conjugated pentadienes, the straight chain and branched chain conjugated hexadienes, other straight and branched chain conjugated dienes having from 4 to 9 carbon atoms, and comonomeric mixtures thereof. The 1,3-butadiene hydrocarbon monomers such as those mentioned hereinbefore provide interpolymers having particularly desirable properties and are therefore preferred. The cost, ready availability and the excellent properties of interpolymers produced therefrom makes 1,3-butadiene the most preferred acyclic aliphatic conjugated diene.

0032Additional monomers can be added to any of the families of copolymers described above, such as, for example the termonomers having homopolymers with an intermediate T_g of greater than 25°C but less than 80°C. Examples of these monomers include 4-biphenyl acrylate, tert-butyl acrylate, vinyl acetate, sec-butyl methacrylate, cyclohexyl methacrylate, ethyl methacrylate, isobutyl methacrylate, propyl methacrylate, isobutyl methacrylate, n-propyl methacrylate and tert-butyl amino ethyl methacrylate.

0033The composite board, e.g. ceiling tiles, can be prepared by any conventional process, such as, for example, water-felted formed on a Fourdrinier process, water-borne (slurried in water) process or cast molded process.

0034The inorganic and cellulosic materials of the composite are conventionally known fillers and fibers. For example, mineral wool (inorganic fiber), perlite or clay (inorganic fillers) and cellulose (cellulosic material).

0035Typical amounts of the binder are from 1 to 25 percent by weight; the cellulosic material. from 5 to 50 percent by weight; the inorganic fiber, from 10 to 70 percent by weight; and the inorganic filler, from 5 to about 90 percent by weight, based upon the total weight of the composite board.

0036The binder system is not limited exclusively to the latex but rather the latex may be all or part of the binder system, e.g. latex plus starch.

0037Ceiling tile is prepared by dispersing newsprint and mixing the dispersion with inorganic and cellulosic material. To this mixture was added the latex, then the flocculant, and the resultant furnish was poured into a mold, diluted and drained. The resultant wet mat was then pressed and dried.

0038The invention is further illustrated, but is not limited by the following examples wherein all parts and percentages are by weight unless otherwise specified.

Example 1

0039Into a 1-liter glass reactor immersed in a temperature controlled water bath were added 359 g of deionized water, 3.0 g of a 1 percent active aqueous pentasodium diethylene triamine pentaacetate solution, and 3.0 g of fumaric acid. The reactor was heated to 60°C to dissolve the fumaric acid and then add 4.5 g of a 33.2 percent solids seed latex containing polystyrene polymer particles was added . The reactor was purged with nitrogen and heated to 85°C and a monomer stream containing 270 g of methyl methacrylate and 27 g of ethyl acrylate was added over a 2-hour period.

0040Beginning at the start of the monomer addition was added over a 2 1/6-hour period, an aqueous stream containing 90.0 g deionized water, 1.5 g sodium persulfate, 0.3 g sodium hydroxide and 3.3 g of a 45 percent active surfactant solution. Following the addition of the monomer and aqueous streams, the reactor was maintained at 85°C for 1 hour, then cooled.

0041The latex was then incorporated as the binder into ceiling tiles in the following manner:

0042Printed newsprint was dispersed in water at 2.0 percent solids. A Cowles blade was used with an air stirrer at high rpm to redisperse the cellulose to a Canadian Standard Freeness of 250-300 mls. Water (4,000 ml), clay (6.0 g), perlite (37.5 g), mineral wool (75.0 g), and the dispersed newsprint (825 ml, 16.5 g of fiber) were mixed for three minutes with moderate agitation using a Cowles blade. Latex (15.0 g of polymer) was added and the slurry was mixed for 30 seconds. Flocculant (cationic polyacrylamide) was added until the latex was completely flocculated (determined by the point when the water became clear). Flocculation was carried out with less than moderate agitation. The flocculated furnish was poured into a Williams Sheet mold apparatus and was diluted to approximately 2.0 percent solids. The furnish was dispersed and drained on a retaining wire. The wet mat was pressed to a thickness of 630 mils (16 mm) and dried at 375° to 400°F (190° to 205°C) in a forced air oven. The resulting board was approximately 8.2 x 8.2 inches (208 x 208 mm), had a thickness of 0.7 inches (18 mm) and a density of 12 lbs/ft³ (19 kg/m³).

Example 2

0043Into a 1-liter glass reactor immersed in a temperature controlled water bath were added 359 g of deionized water, 3 g of a 1 percent active aqueous pentasodium diethylenetriamine pentaacetate solution and 5.06 g of a 27 percent solids seed latex containing polystyrene polymer particles. The reactor was purged with nitrogen and heated to 90°C. Then, a monomer stream containing 255 g of styrene, 18 g acrylic acid and 27 g of ethyl acrylate was added over a 3-hour period.

0044Beginning at the start of the monomer addition was also added over a 3<maths id="math0002"><math display="inline"><mrow><mfrac><mrow><mtext>1</mtext></mrow><mrow><mtext>4</mtext></mrow></mfrac></mrow></math><img file="EP0266850B2_D0004.tif" /></maths>-hour period, an aqueous stream containing 90 g of deionized water, 1.5 g of sodium persulfate, 0.3 g sodium hydroxide and 3.3 g of a 45 percent active surfactant solution. Following the addition of the monomer and aqueous streams, the reactor was maintained at 90°C for 30 minutes, then cooled.

0045A ceiling board was then formulated in the manner described in Example 1.

0046Ceiling boards were prepared as in Example 1 from the following latexes: <tables id="tabl0001" num="0001"><table frame="all"><title>TABLE I</title><tgroup cols="5" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="31.50mm" /><colspec colnum="2" colname="col2" colwidth="31.50mm" /><colspec colnum="3" colname="col3" colwidth="31.50mm" /><colspec colnum="4" colname="col4" colwidth="31.50mm" /><colspec colnum="5" colname="col5" colwidth="31.50mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col5" align="center">Ceiling Board Evaluation</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="center">Example</entry><entry namest="col2" nameend="col2" align="center">Binder</entry><entry namest="col3" nameend="col3" align="center">T_g</entry><entry namest="col4" nameend="col4" align="center">MOR psi (MPA)</entry><entry namest="col5" nameend="col5" align="center">Sag (mm)</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="center">1</entry><entry namest="col2" nameend="col2" align="left">MMA/EA/FA 90/9/1</entry><entry namest="col3" nameend="col3" align="center">106</entry><entry namest="col4" nameend="col4" align="center">170(1.17)</entry><entry namest="col5" nameend="col5" align="center">0.2</entry></row><row><entry namest="col1" nameend="col1" align="center">2</entry><entry namest="col2" nameend="col2" align="left">S/EA/AA 85/9/6</entry><entry namest="col3" nameend="col3" align="center">104</entry><entry namest="col4" nameend="col4" align="center">182 (1.25)</entry><entry namest="col5" nameend="col5" align="center">0.1</entry></row><row><entry namest="col1" nameend="col1" align="center">3</entry><entry namest="col2" nameend="col2" align="left">S/BA/AA 70/24/6</entry><entry namest="col3" nameend="col3" align="center">71</entry><entry namest="col4" nameend="col4" align="center">175 (1.21)</entry><entry namest="col5" nameend="col5" align="center">0.1</entry></row><row><entry namest="col1" nameend="col1" align="center">4</entry><entry namest="col2" nameend="col2" align="left">S/EA/FA 90/9/1</entry><entry namest="col3" nameend="col3" align="center">98</entry><entry namest="col4" nameend="col4" align="center">159 (1.10)</entry><entry namest="col5" nameend="col5" align="center">0.1</entry></row><row><entry namest="col1" nameend="col1" align="center">5</entry><entry namest="col2" nameend="col2" align="left">MMA/EA/FA 80/19/1</entry><entry namest="col3" nameend="col3" align="center">82</entry><entry namest="col4" nameend="col4" align="center">151 (1.04)</entry><entry namest="col5" nameend="col5" align="center">0.5</entry></row><row><entry namest="col1" nameend="col1" align="center">6</entry><entry namest="col2" nameend="col2" align="left">MMA/EA/FA 75/24/1</entry><entry namest="col3" nameend="col3" align="center">78</entry><entry namest="col4" nameend="col4" align="center">163 (1.12)</entry><entry namest="col5" nameend="col5" align="center">0.7</entry></row><row><entry namest="col1" nameend="col1" align="center">Comp. Ex. C</entry><entry namest="col2" nameend="col2" align="left">MMA/BA/FA 65/34/1</entry><entry namest="col3" nameend="col3" align="center">57</entry><entry namest="col4" nameend="col4" align="center">175 (1.21)</entry><entry namest="col5" nameend="col5" align="center">1.0</entry></row><row><entry namest="col1" nameend="col1" align="center">8</entry><entry namest="col2" nameend="col2" align="left">S/B/AA 88/10/2</entry><entry namest="col3" nameend="col3" align="center">86</entry><entry namest="col4" nameend="col4" align="center">150 (1.03)</entry><entry namest="col5" nameend="col5" align="center">0.3</entry></row><row><entry namest="col1" nameend="col1" align="center">Comp. Ex. D</entry><entry namest="col2" nameend="col2" align="left">S/B/AA 81/17/2</entry><entry namest="col3" nameend="col3" align="center">45</entry><entry namest="col4" nameend="col4" align="center">138 (0.95)</entry><entry namest="col5" nameend="col5" align="center">1.0</entry></row><row><entry namest="col1" nameend="col1" align="center">Comparative A</entry><entry namest="col2" nameend="col2" align="left">Starch -</entry><entry namest="col3" nameend="col3" align="center">--</entry><entry namest="col4" nameend="col4" align="center">135 (0.93)</entry><entry namest="col5" nameend="col5" align="center">1.2</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="center">Comparative B</entry><entry namest="col2" nameend="col2" align="left">S/IA 99/1</entry><entry namest="col3" nameend="col3" align="center">106</entry><entry namest="col4" nameend="col4" align="center">100 (0.69)</entry><entry namest="col5" nameend="col5" align="center">0.8</entry></row></tbody></tgroup></table></tables><tables id="tabl0002" num="0002"><table frame="all"><title>TABLE II</title><tgroup cols="2" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="78.75mm" /><colspec colnum="2" colname="col2" colwidth="78.75mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col2" align="center">Monomer Terms</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="center">(S)</entry><entry namest="col2" nameend="col2" align="left">styrene</entry></row><row><entry namest="col1" nameend="col1" align="center">(B)</entry><entry namest="col2" nameend="col2" align="left">butadiene</entry></row><row><entry namest="col1" nameend="col1" align="center">(MMA)</entry><entry namest="col2" nameend="col2" align="left">methyl methacrylate</entry></row><row><entry namest="col1" nameend="col1" align="center">(EA)</entry><entry namest="col2" nameend="col2" align="left">ethyl acrylate</entry></row><row><entry namest="col1" nameend="col1" align="center">(BA)</entry><entry namest="col2" nameend="col2" align="left">butyl acrylate</entry></row><row><entry namest="col1" nameend="col1" align="center">(AA)</entry><entry namest="col2" nameend="col2" align="left">acrylic acid</entry></row><row><entry namest="col1" nameend="col1" align="center">(IA)</entry><entry namest="col2" nameend="col2" align="left">itaconic acid</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="center">(FA)</entry><entry namest="col2" nameend="col2" align="left">fumaric acid</entry></row></tbody></tgroup></table></tables>

0047The table above indicates starch-containing ceiling tile (Comparative A) had a high MOR (high strength) but little sag resistance. The polystyrene latex binder-containing ceiling tile (Comparative B) had moderate sag resistance but a low MOR (little strength).

0048The latex binders of the invention (Examples 1 to 9) have both excellent strength (high MOR) and little sag, i.e,. an MOR of at least 130 psi (0.90 MPa) and a sag of 1 mm or less. Example 3, a copolymer of styrene, butyl acrylate and acrylic acid (70/24/6), is illustrative of the combination of high binder strength - an MOR of 175 psi (1.21 MPa) and high sag resistance - 0.1 mm sag.

0049An entirely different copolymer, Example 1, methyl methacrylate, ethyl acrylate and fumaric acid (90/9/1) also shows high binder strength - MOR of 170 psi (1.17 MPa) - and a high sag resistance - 0.2 mm sag.