Joint filler

Abstract

To provide an organic joint filler which is excellent in wiping workability when filling a joint of a tile surface by a coating joint method, and which can suppress the occurrence of a crack, a gap, etc., in the joint after construction.SOLUTION: The joint filler contains an acrylic silicone resin emulsion and a granular material having a particle diameter of 20 μm or more, wherein the acrylic silicone resin emulsion contains 20 mass% or more of an aromatic monomer in a resin component, and the joint filler has a heating residue of 70 mass% or more.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a novel joint filler. [Background technology]

[0002] Conventionally, joint fillers have been used as materials applied to the joints of tile surfaces composed of multiple tiles. For example, by filling the gaps between the joints (joints) with joint filler, it is possible to improve the aesthetics and waterproofing of the joints, and to repair the joints. As an application method for such joint fillers, the plaster joint method is widely adopted because it is efficient (see, for example, Patent Document 1). The plaster joint method involves applying a paste-like joint filler to the entire tile surface to fill the gaps in the joints, and then wiping off any excess joint filler from the tile surface.

[0003] Inorganic joint fillers, primarily composed of cement, are commonly known as joint fillers. However, because inorganic joint fillers are primarily composed of cement, they must be mixed with water on-site to form a paste, and the color options are limited. Furthermore, inorganic joint fillers lack flexibility, so after application, cracks may occur in the joint filler itself, or gaps may form between the tile and the joint filler.

[0004] In recent years, however, there has been a trend toward using organic joint fillers instead of inorganic ones. Organic joint fillers are paste-like, making them easy to handle on-site, allowing them to be adjusted to the desired color, and offering the advantage of flexibility. However, when organic joint fillers are used to fill joints using the plaster joint filling method, removing excess organic joint filler from the tile surface can be time-consuming, leaving room for improvement in the efficiency of the wiping process. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 5-156781 [Patent Document 2] Japanese Patent Application Laid-Open No. 2010-31542 Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention has been made in consideration of the above-mentioned problems, and aims to provide an organic joint filler that is easy to wipe off when filling the joints on tile surfaces using the joint plaster method, and that can suppress the occurrence of cracks, gaps, etc. in the joints after application. [Means for solving the problem]

[0007] As a result of intensive research into achieving the above-mentioned object, the inventors came up with the idea of ​​a joint filler containing a specific resin emulsion and powder particles having a particle size of 20 μm or more, and having a heating residue of 70 mass % or more, and completed the present invention.

[0008] That is, the present invention has the following features. 1. A joint filler containing an acrylic silicone resin emulsion and powder particles with a particle size of 20 μm or more, The acrylic silicone resin emulsion contains 20% by mass or more of an aromatic monomer in its resin constituent components, The joint filler has a heating residue of 70% by mass or more. A joint filler characterized by: 2. The acrylic silicone resin emulsion contains, as a resin component: (a) a (meth)acrylic acid alkyl ester having an alkyl main chain having 3 or more carbon atoms; (b) an aromatic monomer, and (c) an alkoxysilane compound, 1. The joint filler according to 1., characterized in that it contains 3. The acrylic silicone resin emulsion contains, as a resin component: (a1) a (meth)acrylic acid alkyl ester having an alkyl main chain having 3 to 5 carbon atoms; (a2) (meth)acrylic acid alkyl ester having an alkyl main chain having 6 or more carbon atoms; (b) an aromatic monomer, and (c) an alkoxysilane compound, It includes 1. The joint filler according to claim 1. [Effects of the Invention]

[0009] The joint filler of the present invention is excellent in wiping workability when filling joints on tile surfaces by the joint plastering method, and can also suppress the occurrence of cracks, gaps, etc. in joints after application. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment of the present invention will be described.

[0011] The joint filler of the present invention comprises an acrylic silicone resin emulsion and a powder or granule having a particle size of 20 μm or more, the acrylic silicone resin emulsion containing 20 mass% or more of aromatic monomers in its resin constituents, and the joint filler is characterized in that the heating residue is 70 mass% or more.

[0012] Such a joint filler has excellent wiping workability when filling the joints on tile surfaces using the plaster joint method, and can suppress the occurrence of cracks, gaps, etc. in the joints after application. The reasons for the effects of the present invention are not limited to the following, but it is thought that the wiping workability is improved by the hydrophobic action of the aromatic monomer in the acrylic silicone resin emulsion, the high heat residue of the joint filler, and the relatively low volatile components, etc., which combine to increase drying speed and ultimately improve wiping workability. The suppression of cracks, gaps, etc. in the joints is thought to be due to the flexibility of the acrylic component of the acrylic silicone resin emulsion, the adhesion to the tile side surface due to the silicone component, and the strength provided by the aromatic monomer.

[0013] The acrylic silicone resin emulsion of the joint filler of the present invention functions as a binder. For example, an acrylic silicone resin emulsion containing a (meth)acrylic acid alkyl ester, an aromatic monomer, and an alkoxysilane compound as resin constituents can be used. The ratio of the aromatic monomer in the resin constituents is 20% by mass or more, preferably 25 to 75% by mass, and more preferably 30 to 70% by mass. In the present invention, the acrylic acid alkyl ester and the methacrylic acid alkyl ester are collectively referred to as a (meth)acrylic acid alkyl ester. A monomer is a general term for a compound having a polymerizable unsaturated double bond. In the present invention, "α to β" is synonymous with "α or more and β or less."

[0014] Examples of (meth)acrylic acid alkyl esters include those having an alkyl main chain with 1 to 2 carbon atoms in the alkyl moiety, those having an alkyl main chain with 3 or more carbon atoms in the alkyl moiety, and those having a cyclic alkyl group in the alkyl moiety.

[0015] Among these, the (meth)acrylic acid alkyl ester having an alkyl main chain with 1 to 2 carbon atoms in the alkyl moiety can be one in which the alkyl moiety is a linear or branched alkyl group (excluding cyclic groups) and the main chain (longest linear carbon chain) has 1 to 2 carbon atoms, and examples thereof include methyl (meth)acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, t-butyl (meth)acrylate, etc. These can be used alone or in combination of two or more.

[0016] In a (meth)acrylic acid alkyl ester having an alkyl main chain with 3 or more carbon atoms (hereinafter also referred to as "component (a)"), the alkyl portion is a linear or branched alkyl group (excluding cyclic groups), and the main chain (the longest linear carbon chain) has 3 or more carbon atoms. Component (a) has an alkyl main chain with 3 or more carbon atoms in the alkyl portion. As long as it has such an alkyl main chain, the alkyl portion of component (a) may have various side chains (for example, alkyl groups with fewer carbon atoms than the alkyl main chain). As component (a), any (meth)acrylic acid alkyl ester that satisfies these conditions can be used, for example: (meth)acrylic acid alkyl esters (a1) having an alkyl main chain having 3 to 5 carbon atoms, such as n-propyl (meth)acrylate, isobutyl (meth)acrylate, 1-ethylpropyl (meth)acrylate, t-pentyl (meth)acrylate, neopentyl (meth)acrylate, n-butyl (meth)acrylate, 2-methylbutyl (meth)acrylate, isopentyl (meth)acrylate, 3-methylbutyl (meth)acrylate, 2-ethylbutyl (meth)acrylate, n-pentyl (meth)acrylate, 2-methylpentyl (meth)acrylate, and 4-methylpentyl (meth)acrylate; Examples include (meth)acrylic acid alkyl esters (a2) having an alkyl main chain having 6 or more carbon atoms, such as n-hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, n-heptyl (meth)acrylate, isooctyl (meth)acrylate, n-octyl (meth)acrylate, n-nonyl (meth)acrylate, n-decyl (meth)acrylate, n-undecyl (meth)acrylate, and n-lauryl (meth)acrylate. These can be used alone or in combination of two or more.

[0017] Examples of (meth)acrylic acid alkyl esters having a cyclic alkyl group in the alkyl moiety include cyclohexyl (meth)acrylate, isobornyl (meth)acrylate, dicyclopentanyl (meth)acrylate, and dicyclopentenyl (meth)acrylate.

[0018] Examples of aromatic monomers (hereinafter also referred to as "component (b)") include styrene-based monomers such as styrene, 2-methylstyrene, vinyltoluene, ethylvinylbenzene, vinylnaphthalene, and chlorostyrene, as well as phenyl(meth)acrylate, benzyl(meth)acrylate, and phenoxyethyl(meth)acrylate. These can be used alone or in combination of two or more.

[0019] Examples of the alkoxysilane compound (hereinafter also referred to as "component (c)") include alkoxysilane compounds having a polymerizable unsaturated double bond, such as γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropylmethyldimethoxysilane, γ-methacryloxypropyltriethoxysilane, γ-methacryloxypropylmethyldiethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, and vinyltriisopropoxysilane; Alkoxysilane compounds having a glycidyl group, such as γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropylmethyldimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-glycidoxypropylmethyldiethoxysilane, and 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane; alkoxysilane compounds having an amino group, such as N-2(aminoethyl)3-aminopropyltrimethoxysilane, N-2(aminoethyl)3-aminopropylmethyldimethoxysilane, N-2(aminoethyl)3-aminopropyltriethoxysilane, N-2(aminoethyl)3-aminopropylmethyldiethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, and N-phenyl-3-aminopropyltrimethoxysilane; alkoxysilane compounds having a mercapto group, such as γ-mercaptopropyltrimethoxysilane; Tetramethoxysilane, tetraethoxysilane, tetra-n-propoxysilane, tetra-i-propoxysilane, tetra-n-butoxysilane, tetra-i-butoxysilane, tetra-t-butoxysilane, methyltrimethoxysilane, methyltriethoxysilane, methyltrippropoxysilane, methyltributoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, ethyltrippropoxysilane, ethyltributoxysilane, propyltrimethoxysilane, propyltriethoxysilane, propyltrippropoxysilane, propyltributoxysilane, butyltrimethoxysilane, butyltriethoxysilane, butyltrippropoxy Examples of suitable alkoxysilanes include silane, butyltributoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, dimethyldipropoxysilane, dimethyldibutoxysilane, diethyldimethylsilane, diethyldiethoxysilane, diethyldipropoxysilane, diethyldibutoxysilane, cyclohexylmethyldimethoxysilane, γ-chloropropyltrimethoxysilane, and γ-anilinopropyltrimethoxysilane, as well as modified alkoxysilanes in which at least a portion of the alkoxyl groups of these alkoxysilanes have been modified with a polyoxyalkylene group-containing compound, an amino group-containing compound, a fluorine-containing compound, etc. These can be used alone or in combination of two or more.

[0020] The acrylic silicone resin emulsion may contain other monomers (other monomers) as resin constituents. Examples of such other monomers include: Carboxyl group-containing monomers such as acrylic acid, methacrylic acid, crotonic acid, maleic acid or its monoalkyl ester, itaconic acid or its monoalkyl ester, and fumaric acid or its monoalkyl ester; Carbonyl group-containing monomers such as acrolein, diacetone acrylamide, diacetone methacrylamide, and acetoacetoxyethyl methacrylate; hydroxyl group-containing monomers such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-hydroxyethyl vinyl ether, 4-hydroxybutyl vinyl ether, and 6-hydroxyhexyl vinyl ether; Amino group-containing monomers such as dimethylaminoethyl (meth)acrylate and dimethylaminopropyl (meth)acrylate; Amide group-containing monomers such as (meth)acrylamide and ethyl(meth)acrylamide; nitrile group-containing monomers such as acrylonitrile; Epoxy group-containing monomers such as glycidyl (meth)acrylate; Sulfonic acid-containing vinyl monomers such as styrene sulfonic acid and vinyl sulfonic acid; acid anhydrides such as maleic anhydride and itaconic anhydride; chlorine-containing monomers such as vinyl chloride, vinylidene chloride, and chloroprene; alkylene glycol monoallyl ethers such as ethylene glycol monoallyl ether, propylene glycol monoallyl ether, and diethylene glycol monoallyl ether; vinyl ester monomers such as vinyl acetate and vinyl propionate; Ethylene, propylene, isobutylene, etc. can be used. These can be used alone or in combination of two or more. In addition, an ethylenically unsaturated double bond-containing ultraviolet absorber, an ethylenically unsaturated double bond-containing light stabilizer, etc. can also be used.

[0021] The acrylic silicone resin emulsion of the present invention contains, as a resin component, (a) a (meth)acrylic acid alkyl ester having an alkyl main chain having 3 or more carbon atoms; (b) an aromatic monomer, and (c) an alkoxysilane compound, Such an acrylic silicone resin emulsion is suitable for improving the effects of the present invention. In particular, component (a) contributes to improving wiping workability through its hydrophobic action, and also acts advantageously in terms of flexibility, contributing to preventing the occurrence of cracks, gaps, etc.

[0022] The proportion of component (a) in the resin constituent components is preferably 20 to 80 mass%, more preferably 25 to 75 mass%, and even more preferably 30 to 70 mass%. The proportion of component (b) in the resin constituent components is preferably 20 mass% or more, more preferably 25 to 75 mass%, and even more preferably 30 to 70 mass%. The proportion of component (c) in the resin constituent components is preferably 0.01 mass% or more, more preferably 0.01 to 5 mass%, and even more preferably 0.02 to 3 mass%.

[0023] (a) Component: (a1) a (meth)acrylic acid alkyl ester having an alkyl main chain containing 3 to 5 carbon atoms (hereinafter also referred to as "component (a1)"); It may contain (a2) an alkyl (meth)acrylate ester having an alkyl main chain with 6 or more carbon atoms (hereinafter also referred to as "component (a2)"). When component (a1) and component (a2) are contained as component (a), it is advantageous not only in flexibility but also in strength, and the effect of suppressing cracks, gaps, etc. in joints can be further improved.

[0024] The mass ratio of component (a1) to component (a2) in the resin constituent components preferably satisfies (a1) / (a2) ≧ 0.6, more preferably 10 ≧ (a1) / (a2) ≧ 0.8, even more preferably 8.0 ≧ (a1) / (a2) ≧ 1.0, and particularly preferably 5.0 ≧ (a1) / (a2) ≧ 1.2.

[0025] The acrylic silicone resin emulsion of the present invention can be produced by polymerizing a group of monomers containing the above-mentioned resin constituent components.The polymerization method can be any known method, and in addition to normal emulsion polymerization, soap-free emulsion polymerization, feed emulsion polymerization, seed emulsion polymerization, multi-stage emulsion polymerization, etc. can also be used.During polymerization, for example, emulsifiers, initiators, dispersants, polymerization inhibitors, polymerization retarders, buffers, chain transfer agents, pH adjusters, etc. can be used.

[0026] As the emulsifier, various surfactants that can be used in emulsion polymerization can be used, and these may be reactive types (reactive surfactants) having a polymerizable unsaturated double bond. As the emulsifier, for example, anionic surfactants, nonionic surfactants, cationic surfactants, amphoteric surfactants, etc. can be used alone or in combination.

[0027] The glass transition temperature (Tg) of the acrylic silicone resin emulsion is preferably −50 to 20° C. or less, more preferably −30 to 15° C. The glass transition temperature can be calculated using the Fox formula, provided that component (c) is excluded from the calculation of the glass transition temperature in the present invention.

[0028] The average particle size of the acrylic silicone resin emulsion is preferably 300 nm or less, more preferably 20 to 250 nm, and even more preferably 50 to 200 nm. The average particle size referred to here is a value measured by dynamic light scattering.

[0029] The joint filler of the present invention contains, in addition to the acrylic silicone resin emulsion, a powder having a particle size of 20 μm or more as an essential component. This powder contributes to the ease of application and wiping of the joint filler. Examples of powders include heavy calcium carbonate, light calcium carbonate, clay, kaolin, talc, barium carbonate, white carbon, diatomaceous earth, kansui stone, china clay, barite powder, barium sulfate, precipitated barium sulfate, barium carbonate, magnesium carbonate, silica powder, silica sand, silica stone powder, quartz powder, gravel, hydrous fine silica, aluminum hydroxide, resin beads, glass beads, hollow balloons, metal particles, and crushed rocks, glass, ceramics, shells, sintered bodies, concrete, mortar, plastics, rubber, and the like. These powders can be used alone or in combination. These powders may be colored (colored powders). By using colored powder as the powder, the joint filler can be colored to a desired color.

[0030] The particle size of the powder or granule is 20 μm or more, preferably 20 to 1000 μm, more preferably 32 to 850 μm, and even more preferably 45 to 600 μm. Powder or granules with such particle sizes are suitable for improving the effects of the present invention. The particle size of the powder or granule can be measured by sieving using a metal mesh sieve specified in JIS Z8801-1:2000.

[0031] The mixing ratio (mass ratio) of powder particles having a particle size of 106 μm or more (preferably 106 μm or more but less than 300 μm) to powder particles having a particle size of less than 106 μm (preferably 20 μm or more but less than 106 μm) is preferably 50:50 to 100:0, more preferably 60:40 to 95:5, and even more preferably 70:30 to 90:10. Such an embodiment is preferable in terms of improving the effects of the present invention, and is also suitable in terms of improving workability during application, finish, etc.

[0032] The mixing ratio of the powder and granules is preferably 500 to 1500 parts by mass, more preferably 700 to 1300 parts by mass, and even more preferably 800 to 1200 parts by mass, relative to 100 parts by mass of the solid content of the acrylic silicone resin emulsion. If the powder and granules are mixed in such a ratio, it is suitable in terms of improving the effects of the present invention.

[0033] The joint filler of the present invention can be mixed with fibrous materials in addition to the above-mentioned components. Examples of fibrous materials include synthetic fibers such as pulp fibers, polyester fibers, polypropylene fibers, aramid fibers, vinylon fibers (polyvinyl alcohol fibers), polyethylene fibers, polyarylate fibers, PBO fibers (polyparaphenylene benzobisoxazole fibers), viscose rayon fibers, nylon fibers, acrylic fibers, vinyl chloride fibers, and cellulose fibers; natural fibers such as kenaf, palm, cork, bamboo, hemp, rattan, pineapple, banana, and straw; and inorganic fibers such as rock wool, glass fibers, silica fibers, silica-alumina fibers, carbon fibers, and silicon carbide fibers. These materials can be used alone or in combination. Such fibrous materials are preferred in terms of enhancing the effects of the present invention and are also suitable in terms of improving workability during application and finish.

[0034] The average fiber length of the fibrous material is preferably 0.1 to 5 mm, more preferably 0.2 to 4 mm, and even more preferably 0.3 to 3 mm. The average fiber diameter of the fibrous material is preferably 500 μm or less, more preferably 1 to 200 μm, and even more preferably 2 to 100 μm. The mixing ratio of the fibrous material is preferably 0.1 to 100 parts by mass, more preferably 1 to 80 parts by mass, and even more preferably 3 to 50 parts by mass per 100 parts by mass of the solid content of the acrylic silicone resin emulsion.

[0035] The joint filler of the present invention can be mixed with a color pigment in addition to the above components. In the present invention, the use of a color pigment allows the joint filler to be colored to a desired color. Examples of color pigments include titanium oxide, zinc oxide, alumina, carbon black, graphite, black iron oxide, iron-manganese composite oxide, iron-copper-manganese composite oxide, iron-chromium composite oxide, iron-chromium-cobalt composite oxide, copper-chromium composite oxide, copper-manganese-chromium composite oxide, copper-magnesium composite oxide, bismuth-manganese composite oxide, ferric oxide (red iron oxide), molybdate orange, permanent red, permanent carmine, anthraquinone red, perylene red, quinacridone red, yellow iron oxide, titanium yellow, fast yellow, benzimidazolone yellow, chrome green, cobalt green, phthalocyanine green, ultramarine blue, Prussian blue, cobalt blue, phthalocyanine blue, quinacridone violet, dioxazine violet, aluminum pigments, and pearl pigments. These pigments can be used alone or in combination of two or more. The average particle size of the color pigment is preferably 10 μm or less, more preferably 1 μm or less, and even more preferably 0.01 to 0.9 μm. The average particle size of the color pigment is a value measured by a laser diffraction particle size distribution analyzer.

[0036] The mixing ratio of the color pigment is preferably 0.1 to 80 parts by mass, more preferably 0.3 to 40 parts by mass, and even more preferably 0.5 to 30 parts by mass, per 100 parts by mass of the solid content of the acrylic silicone resin emulsion. By keeping the content of the color pigment within this range, the joint filler can be colored to the desired color.

[0037] In addition to the above-mentioned components, the joint filler of the present invention can be mixed with various additives as needed, such as pH adjusters, plasticizers, preservatives, antifungal agents, anti-algae agents, defoamers, leveling agents, coupling agents, dispersants, anti-settling agents, anti-sagging agents, thickeners (thixotropic adjusters), film-forming aids, matting agents, crosslinking agents, catalysts, curing accelerators, adhesion promoters, UV absorbers, light stabilizers, solvents, and water. If necessary, resin components other than the above-mentioned acrylic silicone resin emulsion, powder particles of different particle sizes from the above-mentioned powder particles, etc. can also be mixed. The joint filler of the present invention can be produced by uniformly mixing the above-mentioned acrylic silicone resin emulsion, powder particles, and various additives as needed using conventional methods.

[0038] The joint filler of the present invention can be embodied as including a crosslinking agent. The use of a crosslinking agent is preferred in terms of improving the effects of the present invention. In this case, an acrylic silicone resin emulsion having reactive functional groups is used as the resin, and a crosslinking agent capable of reacting with the reactive functional groups is used as the crosslinking agent. Suitable combinations of reactive functional groups include, for example, combinations of carboxyl groups and carbodiimide groups, carboxyl groups and epoxy groups, carboxyl groups and oxazoline groups, carbonyl groups and hydrazide groups, and alkoxysilyl groups, and the like. One or more of these can be used. Carboxyl group-containing acrylic silicone resin emulsions can be obtained by using carboxyl group-containing monomers as resin constituents. Carbonyl group-containing acrylic silicone resin emulsions can be obtained by using carbonyl group-containing monomers as resin constituents.

[0039] Among these, examples of crosslinking agents having a carbodiimide group include those described in JP-A-10-60272, JP-A-10-316930, JP-A-11-60667, JP-A-2000-7642, JP-A-2000-119539, JP-A-2000-319351, JP-A-2013-112755, JP-A-2016-196612, JP-A-2016-196613, WO2017 / 6950, etc. These can be used alone or in combination of two or more.

[0040] Examples of crosslinking agents having an epoxy group include ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyhydroxyalkane polyglycidyl ether, sorbitol polyglycidyl ether, etc. These may be used alone or in combination of two or more.

[0041] Examples of crosslinking agents having an oxazoline group include resins obtained by copolymerizing polymerizable oxazoline compounds such as 2-vinyl-2-oxazoline, 2-vinyl-4-methyl-2-oxazoline, 2-vinyl-5-methyl-2-oxazoline, and 2-isopropenyl-2-oxazoline with monomers copolymerizable with the compounds. These can be used alone or in combination of two or more.

[0042] Examples of crosslinking agents having a hydrazide group include malonic acid dihydrazide, succinic acid dihydrazide, glutaric acid dihydrazide, adipic acid dihydrazide, sebacic acid dihydrazide, maleic acid dihydrazide, etc. These can be used alone or in combination of two or more.

[0043] As the crosslinking agent having an alkoxysilyl group, for example, various alkoxysilane compounds in acrylic silicone resin emulsions can be used, specifically, alkoxysilane compounds having a glycidyl group, alkoxysilane compounds having an amino group, etc. These can be used alone or in combination of two or more.

[0044] The ratio of the crosslinking agent is preferably 0.05 to 50 parts by mass, more preferably 0.1 to 20 parts by mass, calculated as solid content, relative to 100 parts by mass of the solid content of the acrylic silicone resin emulsion.

[0045] The joint filler of the present invention is an aqueous paste-like material containing water as a medium (i.e., containing an aqueous medium). The aqueous medium may contain a water-soluble solvent in addition to water, as needed. Examples of water-soluble solvents include alcohols, glycols, glycol ethers, etc. Among these, when alcohols such as methanol, ethanol, and isopropyl alcohol are contained, the drying property is improved and it is also preferable in terms of wiping workability.

[0046] The joint filler of the present invention has a heating residue of 70% by mass or more, preferably 70 to 95% by mass, and more preferably 75 to 90% by mass. Having a heating residue within the above range ensures ease of wiping and is also suitable in terms of application workability and finish. The heating residue is a value measured in accordance with the method of JIS K5601-1-2 "Heating residue" under conditions of a heating temperature of 135°C and a heating time of 60 minutes.

[0047] The viscosity of the joint filler of the present invention is preferably 30 to 300 Pa·s, more preferably 40 to 200 Pa·s. The effects of the present invention can be stably achieved by keeping the viscosity of the joint filler (or the diluted joint filler if diluted) within this range. The viscosity referred to here is a value determined by measuring the viscosity at 2 rpm (the index value at the second rotation) using a BH-type viscometer, and the measurement temperature is 23°C.

[0048] The joint filler of the present invention can be preferably applied to tile surfaces of buildings, civil engineering structures, etc. Examples of tile types include porcelain tiles, stoneware tiles, semi-porcelain tiles, and ceramic tiles. Examples of such tile surfaces include those formed by applying a base mortar to a substrate, adhering tiles with a covering mortar, and filling the joints with joint mortar, or those formed by applying an organic adhesive to the entire surface of the substrate and adhering tiles at predetermined intervals, with the organic adhesive appearing as joints. Therefore, the mortar or organic adhesive is exposed at the joints between the tiles. The width of the joints is preferably approximately 3 to 10 mm.

[0049] The joint filler of the present invention can be used, for example, as a material for repairing the joints of such tile surfaces using a plaster joint method. In the plaster joint method, the joint filler is first applied to the entire tile surface (the entire surface including the tile surface and the joints) to fill the gaps in the joints, and then excess joint filler is wiped off the tile surface. Tools such as a trowel or spatula can be used to apply the joint filler. After applying the joint filler, scraping the joint filler off the tile surface with a trowel or spatula can reduce the effort required for the subsequent wiping step. Tools such as a cloth, sponge, or brush can be used to wipe off the joint filler from the tile surface. The wiping step can be started approximately when the joint filler on the tile surface begins to dry after application. In the present invention, by using the joint filling method using the above-mentioned joint filler, the joint gaps (joints) can be filled with the joint filler while efficiently wiping the tile surface, and the aesthetics and waterproofness of the joints can be improved.

[0050] The application, drying, and wiping of the joint filler can be carried out in an environment at room temperature (preferably 0 to 50°C, more preferably 5 to 45°C). The drying time of the joint filler at room temperature is preferably 2 hours or more, more preferably 3 hours or more. [Example]

[0051] The following examples will be given to clarify the features of the present invention, but the present invention is not limited to these examples.

[0052] (Manufacturing of joint fillers) Each joint filler was manufactured by mixing and stirring the raw materials in the usual manner according to the formulation shown in Table 1. The raw materials used were as follows.

[0053] Resin 1: Acrylic silicone resin emulsion (emulsion polymer of 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 42:54:1:3), (a1) / (a2)=0, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 3°C, medium: water) Resin 2: Acrylic silicone resin emulsion (emulsion polymer of n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 18:26:52:1:3), (a1) / (a2) = 0.69, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 5°C, medium: water) Resin 3: Acrylic silicone resin emulsion (emulsion polymer of n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 24:22:50:1:3), (a1) / (a2) = 1.09, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 3°C, medium: water) Resin 4: Acrylic silicone resin emulsion (emulsion polymer of n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 26:20:50:1:3), (a1) / (a2) = 1.30, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 4°C, medium: water) Resin 5: Acrylic silicone resin emulsion (emulsion polymer of methyl methacrylate, n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 12.5:34:13:36:1.5:3), (a1) / (a2) = 2.62, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 4°C, medium: water) Resin 6: Acrylic silicone resin emulsion (emulsion polymer of methyl methacrylate, n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 8:39.5:9:40:0.5:3), (a1) / (a2) = 4.39, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 4°C, medium: water) Resin 7: Acrylic silicone resin emulsion (emulsion polymer of n-butyl acrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 28:18:50:1:3), (a1) / (a2) = 1.56, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 4°C, medium: water) Resin 8: Acrylic silicone resin emulsion (emulsion polymer of methyl methacrylate, 2-ethylhexyl acrylate, styrene, γ-methacryloyloxypropyltrimethoxysilane, and methacrylic acid (mass ratio 44:42:10:1:3), (a1) / (a2)=0, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 5°C, medium: water) Resin 9: Acrylic resin emulsion (emulsion polymer of 2-ethylhexyl acrylate, styrene, and methacrylic acid (mass ratio 42:55:3), (a1) / (a2)=0, average particle size: 150 nm, solid content: 50% by mass, glass transition temperature: 4°C, medium: water)

[0054] ·Powder 1: Silica sand (particle size: 53~300μm, Powder particle ratio of 106 μm or more and less than 300 μm: 85% by mass, Powder particle ratio of 20 μm or more and less than 106 μm: 15% by mass ·Powder 2: Silica sand (particle size: 45~212μm, Powder particle ratio of particle size 106 μm or more and less than 300 μm: 72% by mass, Powder particle ratio of particle size 20 μm or more and less than 106 μm: 28% by mass ·Powder 3: Silica sand (particle size: 20~38μm, Powder particle ratio of particle size 106 μm or more and less than 300 μm: 20% by mass, Powder particle ratio of 20 μm or more and less than 106 μm: 80% by mass

[0055] Color pigment: Black pigment dispersion (carbon black 20% dispersion) Crosslinker: γ-glycidoxypropyltrimethoxysilane Water-soluble solvent: Methanol Fiber material: Vinylon fiber (fiber length 0.8 mm) Dispersant: Anionic dispersant Coalescence agent: Ester-based coalescence agent Thickener: Hydroxyethyl cellulose aqueous solution (solid content 3% by mass) Antifoaming agent: Silicone-based antifoaming agent

[0056] (Test 1) The test substrate was prepared by applying a modified silicone elastic adhesive to the entire surface of a slate board, then attaching ceramic tiles with 5mm-wide joints. The test substrate was then placed vertically, and joint filler was applied to the entire surface with a trowel. After filling the joints with the joint filler, the joint filler on the tile surface was scraped off with the trowel. After the joint filler on the tile surface was dry to the touch, it was wiped off with a damp sponge. All of the above procedures were carried out under standard conditions (temperature 23°C, relative humidity 50%).

[0057] In Evaluation 1-1, the ease of application of the joint filler was evaluated. The evaluation was conducted on a four-point scale (excellent: AA>A>B>C: poor), with "AA" being given to those who were able to apply the joint filler and fill the joints reliably and smoothly, and "C" being given to those who were not.

[0058] In evaluation 1-2, the wiping workability of the joint filler was evaluated. The evaluation was conducted on a four-point scale (excellent: AA>A>B>C: poor), with "AA" being given to those who were able to reliably and smoothly wipe off the joint filler from the tile surface and had excellent wiping workability, and "C" being given to those who were not.

[0059] (Test 2) The specimens obtained by the method in Test 1 above were cured for 14 days under standard conditions, and then subjected to a total of 10 cycles of repeated heating and cooling, with one cycle consisting of 18 hours of water immersion, 3 hours of rest at -20°C, and 3 hours of rest at 50°C, after which the appearance (the presence of defects such as cracks and gaps) was visually inspected. The evaluation was conducted on a four-point scale (excellent: AA>A>B>C: poor), with "AA" being given for no defects and "C" being given for clear defects. did.

[0060] (Test results) The test results are shown in Table 1. Good results were obtained in all tests for Examples 1 to 14. Note that Test 2 was not carried out for Comparative Example 3, as it was evaluated as being poor in Test 1.

[0061] [Table 1]

Claims

1. A joint filler containing an acrylic silicone resin emulsion and a powder having a particle size of 20 μm or more, The acrylic silicone resin emulsion contains 20% by mass or more of an aromatic monomer in its resin constituent components, The joint filler has a heating residue of 70% by mass or more. A joint filler characterized by:

2. The acrylic silicone resin emulsion contains, as a resin component: (a) a (meth)acrylic acid alkyl ester having an alkyl main chain having 3 or more carbon atoms; (b) an aromatic monomer, and (c) an alkoxysilane compound; 2. The joint filler of claim 1, comprising:

3. The acrylic silicone resin emulsion contains, as a resin component: (a1) a (meth)acrylic acid alkyl ester having an alkyl main chain having 3 to 5 carbon atoms; (a2) (meth)acrylic acid alkyl ester having an alkyl main chain having 6 or more carbon atoms; (b) an aromatic monomer, and (c) an alkoxysilane compound; It includes 2. The joint filler according to claim 1.

Images