Document yp1drpqDvVrapBOV8ggEdwRj2

TAPE JOINT CEMENTS BY WILLIAM D. MASSEY PLAINTIFF'S EXHIBIT UC-1008 1978 SALES TRAINING PROGRAM TRADE FINISHES UNION CARBIDE TECHNICAL CENTER SOUTH CHARLESTON, WEST VIRGINIA 25303 ^ ^3 4 Og 2- - TAPE JOINT CEMENTS Wide usage of gypsum wallboard in the building in dustry necessitates a large amount of material to cover and provide a smooth surface over wallboard joints and nailhead indentations. Tape joint cements (TJC) are low-cost composi tions formulated to fill this need and to meet other necessary economic and performance properties required by modern building methods. Tape joint cements are supplied as a ready-mix or as a dry powder which is mixed with water at the construction site. The convenient ready-mix eliminates many construction site pro blems caused by mixing water into dry mix formulations. As a result, ready-mix usage has grown rapidly at the expense of dry mix compositions. Ready-mix joint cements are highly filled compositions generally consisting of blends of a calcium carbonate filler, a clay filler, a platy filler such as mica, a polyvinylacetate latex binder, a water-soluble cellulosic thickener, and various minor ingredients such as preservatives, freeze-thaw agents, and dispersing aids. The fillers contribute over 90 percent by weight of the solids in the formulation with calcium carbonate forming the largest part of the filler mix. Latex solids con tribute -approximately 3.0 to 5.0 percent by weight of the solids. Cellulosic thickeners are vital to performance properties but contribute less than one-half percent by weight to the solids. Water content, which depends on the choice of fillers, thickener, A23407 -3 - and the necessary application viscosity, varies from 25 to 35 percent by weight of the finished ready-mix. The tape joint cement market is highly competitive and extremely cost conscious. The major raw material costs in ready-mix are the latex binder, the cellulosic thickener, and the various additives. As a result, raw material suppliers are under competitive pressure to reduce costs of these materials. Union Carbide currently supplies polyvinylacetate latex and cellulosic thickeners to TJC manufacturers. Several CELLOSIZE thickeners are suitable for use in TJC manufacture with CELLOSIZE TJC-500 especially designed for this area. UCAR 131 currently enjoys the position as the dominant latex binder in the ready-mix market. However, this position is constantly being threatened by new competitive binders. 423408 ( TAPE JOINT CEMENT PROPERTY REQUIREMENTS LOW COST ( WORKABILITY LOW SHRINKAGE CRACK RESISTANCE SUFFICIENT OPEN TIME ADHESION UNDER A VARIETY OF CONDITIONS SAG RESISTANCE v 423409 TJC FORMULATION INGREDIENTS WATER ETHYLENE GLYCOL "CELLOSIZE" QP-52M AMMONIUM HYDROXIDE "UCAR" 131 DOWICIL 75 DAXAD 30 LIMESTONE TALC MICA PARTS BY WEIGHT 27.25 .35 .42 .07 4.89 .07 .56 60.80 3.49 2.10 100.00 RMC 0.000 .091 .672 .006 1.027 .105 .196 .638 .061 .099 2.895 4234 1C TAPE JOINT CEMENT INTERMEDIATES TPX-6307 "UCAR" 134 "UCAR" 131 "UCAR" 130 "CELLOSIZE" TJC-500 "CELLOSIZE" QP-4400 "CELLOSIZE" QP-15,000 "CELLOSIZE" QP-52,000 "CELLOSIZE" QP-100,000 PROPYLENE GLYCOL ETHYLENE GLYCOL LATEX AIRFLEX 527BP AIRFLEX 526BP AMSCO 4104 ELVACE 1875 PLYAMUL 40-375 PLYAMUL 40-376 TAPE JOINT CEMENT COMPETITIVE BINDERS S 55 55 49.7 55 58 60 COMPOSITION ETHYLENE - VINYL ACETATE ETHYLENE - VINYL ACETATE STYRENE - BUTADIENE ETHYLENE - VINYL ACETATE PLASTICIZED VA PLASTICIZED VA TAPE JOINT CEMENT COMPETITIVE THICKENERS METHOCEL J75MS METHOCEL 228 NATROSOL 25OH TYPICAL PROPERTIES OF TPX-6307 (a) Total Solids pH Viscosity (b) Minimum Filming Temperature Glass Transition (T ) r Weight Per Gallon oi Latex Reaction to Borax Reaction to Heavy Metallic Ions 59.0% 5.5 4000 cps 1.5 C 8 C 9.2 1 bs. Stable Coagulates (a) Should not be regarded as specifications. (b) 60 RPM, Brookfield. TYPICAL PROPERTIES OF "UCAR" 134 TOTAL SOLIDS VISCOSITY pH MINIMUM FILMING TEMPERATURE GLASS TRANSITION WEIGHT PER GALLON OF LATEX REACTION TO BORAX REACTION TO HEAVY METAL IONS 59.8% 490 CPS 5.0 15.5C 15C 9.2 STABLE STABLE 423 LS TJC FORMULATION 2-WDM-29 Ingredients Water Ethylene Glycol Ammonium Hydroxide Dowici1 75 Latex (a) Daxad 30 Limestone #9 White Mica P-80-F ASP-400 Attagel 40 Parts by Weight 455.0 15.0 2.0 1.0 89.5 . 10.0 780.0 175.0 80.0 10. 0 (a) Latex weight adjusted to provide equal latex solids in each formulation. ^23416 f PERFORMANCE PROPERTIES IN TJC FORMULATION 2-WDM-29 Latex % f Viscosity TPC-6307 68.0 520 UCAR 131 68.3 540 UCAR 134 68.2 550 14-TRS-71C 67.4 510 R. T. Crack Workabilityk Adhesion Resistance 8 62% 93% 8 96% 95% 8 81% 100% 8 78% 88% (a) Brabender Units, 80 rpm. (b) Rating Scale 1-10 with 10 an excellent rating. (c) Laboratory run ol TPX-6307. A234 1 7 TJC FORMULATION 7-WDM-78 Ingredients Water Ethylene Glycol QP-52,000 Ammonium Hydroxide Dowicil 75 Latex (a) Daxad 30 Limestone #9 White Talc T-50 ASP-400 Parts by Weight 370.0 5.0 6.0 i.O 1.0 70.0 8.0 810.0 100.0 40.0 (a) Latex weight adjusted to give equal latex solids in each formulation. A23418 PERFORMANCE PROPERTIES IN TJC FORMULATION 7-WDM-78 Latex %S UCAR 131 70.8 UCAR 134 70.8 TPX-6307 70.7 Dupont JCM 70.3 Airflex 526BP 70. 1 Viscosity 540 540 545 560 560 Workability 9 9 9 9 9 R.T. Adhesion 97% 90% 81% 96% 93% Cra ck Resistance 74% 77% 82% 74% 90% A234 1 g TAPE JOINT CEMENT FORMULATION STUDY SUMMARY Ingredients used in manufacture of tape joint cement were evaluated in several asbestos-free formulations. An experimental design with talc, mica, and clay levels and CELLOSIZE thickener types as variables was used to minimize the number of formulations made and tested. ' The variables chosen provide a possible 81 formula tions of which nine were made and evaluated. Data analysis establishes an order of influence for each variable on measured performance properties. For example, room temperature adhesion decreases with increasing talc content; crack resistance and workability improve with increasing talc content. This approach allows selection of ingredient levels within the design limits which maximizes any desired performance property. Formulations were based on total solids. Latex solids were set at 4.2%, thickener solids at 0.6%, and dispersant solids at 0.2%. Talc, mica, and clay percent solids and thickener type were varied according to the design. Limestone solids varied with each formulation so that solids persent totaled 100. Initial volatiles were adjusted to produce 70% total solids. If the initial viscosity was greater than 550 B.U., water was added to bring viscosity to 500-550 B.U. 623^2." EXPERIMENTAL DESIGN VARIABLES TALC T-50 MICA P-80-F CLAY, ASP-400 CELLULOSIC THICKENER QP-52M TJC-500 QP-52M/QP-100M (1:1) VARIABLE LEVELS AND DESIGNATION Tl' 5% m2. 0% T2' 10% Mj, 3% T3 ' 15% m3, 6% Al' 0% A2' 2% A3 * 4% A23421 DESIGN 74 T1M1 A1C1 77 TlM2 A2C2 80 T1M3 A3C3 75 t2m2 a2c3 78 T2M2 a2c1 81 T2M3 A1C2 76 T3M1 A3C2 79 T3M2 a1c3 82 T3M3 a2Ci R.T. Adhesion Talc Mica ASP-400 Thickener Crack Resistance Talc Mica ASP-400 Thickener Workability Talc Mica ASP-400 Thickener EXPERIMENTAL DESIGN Order of Influence on Property l<a> 2 3 Tl T2 T3 M2 Ml M3 a2 a3 A1 C3 Cl C2 T3 T2 Tl M3 Ml M2 a3 A1 A2 Cl C2 c3 t3 T2 Ti Mi m3 M2 a3 A1 a2 c3 Cl c2 (a) Variables in Column 1 have the largest influence on A 0 measured properties. ^ t>>> t< in in n Si 1 in in in Xtuf 00 a Cl CD Cl Cl Cl 00 Cl fe jaoB O tf tf u(-1 6% To-amaV<s>> GlOiHCDOC'-OOCli-l r-oooicooot^t^oo ci a o H -rl (0 ja:> <! CMCMOOOOOOOOOin inCDCMC-inCO^'iHCM SUMMARY OF TJC FORMULATION PROPERTIES Rated from 1-10 w ith 10 in d ic a tin g e x c e lle n t w o rk a b ility Cl CD CO Cl Cl CO o CD CM 9* Cl CT) o Cl Cl 01 Cl Cl 00 6* CO CO CO CO CO CO co CO CO tf+>J1 m o in m o o o o o o o o 'S' CM 'S' co CM iH CM CO o0H) in n in CO Tf in m in m > a o +> as 3 VOei tIfe CrD r oo i ii 01 O t- . 00 II iH CM 00 00 II tf.no A23423 TJC FORMULATION 7WDM74 Ingredients Water Ethylene Glycol QP-52M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 390.0 5.0 6.0 1.0 70.0 1.0 8.0 870.0 50.0 30.0 0.0 1431.0 Gallons 46.82 .54 .55 .12 7.61 .10 .84 38.67 2.22 1.29 0.0 98.76 A23424 TJC FORMULATION 7WDM75 Ingredients Water Ethylene Glycol QP-52M/QP-100M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 395.0 5.0 6.0 1.0 70.0 1.0 8.0 800.0 100.0 30.0 20.0 1436.0 Gallons 47.42 .54 .55 .12 7.61 .10 .84 35.56 4.44 1.29 .93 99.40 A2342S TJC FORMULATION 7WDM76 Ingredients Water Ethylene Glycol TJC-500 NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 395.0 5.0 6.0 1.0 70.0 1.0 8.0 730.0 150.0 30.0 40.0 1436.0 Gallons 47.42 .54 .55 .12 8.61 .10 .84 32.44 6.67 1.29 1.86 99.44 TJC FORMULATION 7WDM77 Ingredients Water Ethylene Glycol TJC-500 NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 390.0 5.0 6.0 1.0 70.0 1.0 8.0 880.0 50.0 0.0 20.0 1431.0 Gallons 46.82 .54 .55 .12 7.61 .10 .84 39.11 2.22 0.00 .93 98.84 A 24 ? 7 TJC FORMULATION 7WDM78 Ingredients Water Ethylene Glycol QP-52M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 390.0 5.0 6.0 1.0 70.0 1.0 8.0 810.0 100.0 0.0 40.0 1431.0 Gallons 46.82 .54 .55 .12 7.61 .10 .84 36.00 4.44 0.00 1.86 98.88 ( ' TJC FORMULATION 7WDM79 Ingredients Water Ethylene Glycol QP-52M/QP-100M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 0 0 Pounds 395.0 5.0 6.0 1.0 70.0 1.0 8.0 800.0 150.0 0.0 1436.0 00 Gallons 47.42 .54 .55 .12 7.61 .10 35.56 6.67 0.00 0.00 99.41 <v A23429 TJC FORMULATION 7WDM80 Ingredients Water Ethylene Glycol QP-52M/QP-100M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 Pounds 408.0 5.0 6.0 1.0 70.0 1.0 8.0 800.0 50.0 60.0 40.0 1449.0 Gallons 48.98 .54 .55 .12 7.61 .10 .84 35.56 2.22 2.57 1.86 100.95 TJC FORMULATION 7WDM8I Ingredients Water Ethylene Glycol TJC-500 NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 0 0 0 ao Pounds 395.0 5.0 6.0 1.0 70.0 1.0 790.0 100.0 60.0 1436.0 Gallons 47.42 .54 .55 .12 7.61 .10 .84 35.11 4.44 2.57 0.00 99.30 A2343 1 TJC FORMULATION 7WDM82 Ingredients Water Ethylene Glycol QP-52M NH4OH UCAR 131 Dowicil 75 Daxad 30 Limestone # 9 Talc T-50 Mica P-80-F ASP-400 0 00 Pounds 425.0 5.0 6.0 1.0 70.0 1.0 720.0 150.0 60.0 20.0 1466.0 Gallons 51.02 .54 .55 .12 7.61 .10 .84 32.00 6.67 2.570.93 102.95