Polyvinyl chloride (PVC) composition and building materials made therefrom

Abstract

A composition comprising a thermoplastic comprising approximately 20 to 40% of the composition, a thermoset comprising approximately 5 to 20% of the composition, a filler comprising approximately 10 to 80% of the composition, the filler including at least one of: a nonflammable inorganic; and a nonflammable organic, and approximately 2.2 to 30% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer. The composition may be used in forming a wallboard or other building materials.

Description

Attorney Docket No.: OBSP101WO POLYVINYL CHLORIDE (PVC) COMPOSITION AND BUILDING MATERIALS MADE THEREFROM FIELD

[0001] The present disclosure generally relates to the technical field of polyvinyl chloride (PVC) compositions and building materials made therefrom, and also to a composition yielding building materials, such as an improved “drywall” or wallboard, having water resistance, fire retardancy, impact resistance, and reduced shrinkage at elevated temperatures. BACKGROUND

[0002] Polyvinyl chloride (PVC) is generally considered a versatile thermoplastic polymer. In its various forms, it is widely used in the building and construction industry for various building materials. PVC is the world’s third-largest thermoplastic by volume after polyethylene and polypropylene. Typically, PVC is a white, brittle solid material available in powder form or granules. In the past decade, PVC has been replacing traditional building materials in several applications. These materials include wood, metal, concrete, rubber, ceramics, etc., in several applications. This is due to its versatile properties, including but not limited to: weight reduction, durability, low cost, and general ease of processability.

[0003] One example of a traditional building material is traditional gypsum wallboard, or gypsum board. Gypsum board, more commonly known as and referred to as “drywall”, is the standard building material for wall, ceiling, and partition systems in residential, institutional, and commercial structures. It is known for having inherent fire resistance. Gypsum boards are designed to provide a monolithic surface when joints and fastener heads are covered with a joint treatment system (i.e., joint compound). However, due to the high content of inorganic material, gypsum boards exhibit poor water resistance and generally have substantial mass.

[0004] These drywall boards provide only nominal sheer strength and usually require a one- inch depth to achieve a 1-hour UL firing rating.

[0005] Thus, there is a need for a gypsum board replacement that improves at least its poor water resistance and substantial mass. Such solutions have been contemplated. Examples include: U.S. Published Patent Application No. 2022 / 0403155 (hereinafter Yocca et al.), filed April 25, 2022; U.S. Published Patent Application No.2022 / 0389152 (hereinafter Sun et al.), filed April 22,2022; and, U.S. Patent No.7,211,625 (hereinafter Tsuji et al.), filed September 22, 2003, which applications are incorporated by reference herein in their entireties. However, such examples fail to disclose a particular composition of an inorganic filler and thus, do not speak to sufficient mass reduction of a wallboard, or building material derived therefrom.

[0006] Therefore, there is a long-felt need for a PVC composition for use as a building material such as a wallboard, which composition complies with UL fire rating requirements at a depth of a wallboard being less than one-inch, an overall reduction of mass when the composition is formed as a wallboard, i.e., lighter than traditional gypsum boards, and the wallboard, formed from the PVC composition having greater shear strength than traditional gypsum boards.

[0007] Further, prior attempts also suggest a need for a composition, a PVC composition, which may be formed into a plurality of building materials, such as a wallboard, where the wallboard possesses water resistance, fire retardancy, impact resistance, and reduced shrinkage at elevated temperatures. SUMMARY

[0008] In a broad aspect, the disclosure describes a composition, or formulation, comprising a blend of PVC, reactive monomers, inorganic fillers, foaming agents, tougheners, lubricants, and stabilizers. This combination is aimed to provide a thermoset polymer composition, which may be formed into an article of manufacture, e.g., a building material such as a wallboard, which article possess fire retardancy, impact-resistance, and lightweight properties.

[0009] In some embodiments, the present invention generally comprises a composition which includes a thermoplastic comprising approximately 20 to 40% of the composition, a thermoset comprising approximately 5 to 20% of the composition, a filler comprising approximately 10 to 80% of the composition, the filler including at least one of: a nonflammable inorganic; and a nonflammable organic, and approximately 2.2 to 30% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

[0010] In other configurations, the invention may comprise a wallboard made from the aforementioned composition.

[0011] In some aspects, the thermoplastic of the composition comprises polyvinyl chloride.

[0012] In other embodiments, the filler of the composition comprises at least one of: glass fiber, light calcium carbonate, and TiO2pigment.

[0013] In some configurations, the thermoset of the composition may comprise at least one of an acrylate and methacrylate.

[0014] In some arrangements, the thermoset of the composition includes at least one of: tetrahydrofurfuryl acrylate (THFA); dicumyl peroxide (DCP); and, dipropylene glycol diacrylate (DPGDA).

[0015] In other embodiments, the composition may further comprise at least one additive comprising approximately 1 to 5% of the composition.

[0016] In some arrangements, the wallboard made from the aforementioned composition may further include a top end; a bottom end; a first side end having a groove arranged therein and spanning the first side from top end and the bottom end; and, a second side arranged opposite the first side, the second side having a protruding portion extending therefrom and spanning the second side from the top end to the bottom end.

[0017] In a preferred embodiment, the aforementioned composition may comprise the thermoplastic, which thermoplastic is polyvinyl chloride and comprises approximately 25% of the composition, the thermoset, which thermoset includes: tetrahydrofurfuryl acrylate (THFA), dicumyl peroxide (DCP), and dipropylene glycol diacrylate (DPGDA), and further, the thermoset comprising approximately 11.2% of the composition, and the filler including: glass fiber, light calcium carbonate, and TiO2pigment, where the filler comprising approximately 55.6% of the composition.

[0018] In further aspects, the composition comprises approximately 8.2% of: the at least one foaming agent; the foaming regulator; the fire retardant; the at least one lubricant; and, the at least one thermal stabilizer.

[0019] Alternatively, the present invention may generally take the form of a thermoplastic composition, which composition comprises a thermoplastic comprising approximately 25% of the composition, the thermoplastic being polyvinyl chloride, a thermoset comprising approximately 11.2% of the composition, the thermoset including: tetrahydrofurfuryl acrylate (THFA), dicumyl peroxide (DCP), and dipropylene glycol diacrylate (DPGDA), an inorganic filler comprising approximately 55.6% of the composition, the inorganic filler including: glass fiber, light calcium carbonate, and TiO2pigment, and approximately 8.2% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

[0020] In some aspects, the aforementioned composition may be used and / or formed as at least one of: a wallboard, a plumping pipe, and a spreadable sealant.

[0021] In other embodiments of the aforementioned composition, the at least one foaming agent comprising sodium bicarbonate and azodicarbonamide, the foaming regulator comprises poly (methyl methacrylate), the fire retardant comprises chlorinated polyethylene, the at least one lubricant comprising stearic acid and polyethylene wax, and the at least one thermal stabilizer comprising zinc stearate and calcium stearate, whereas in other arrangements, the sodium bicarbonate and azodicarbonamide comprise approximately 0.9% of the composition, the poly (methyl methacrylate) comprises approximately 1.5% of the composition, the chlorinated polyethylene comprises approximately 3.3% of the composition, the stearic acid and polyethylene wax comprise approximately 0.9% of the composition, and the zinc stearate and calcium stearate comprise approximately 1.6% of the composition.

[0022] In further embodiments, the light calcium carbonate of the aforementioned composition comprises approximately 47% of the composition.

[0023] In other arrangements, the glass fiber of the aforementioned composition comprises approximately 8% of the composition.

[0024] In some embodiments, the TiO2pigment of the aforementioned composition comprising approximately 0.6% of the composition.

[0025] An object of the invention is to provide a formulation of a wallboard which has improved water resistance properties. Thus, one aspect of the invention is a wallboard composed of a blend of polyvinyl chloride polymer, acrylate monomers, one or more thermal radical initiators, polymeric oligomers, lightweight inorganic fillers, calcium carbonate, foaming agents, foaming regulators, flame retardant tougheners, waxes which act as internal and external lubricants, stabilizers, and pigments.

[0026] These and other objects, features, and advantages of the present invention will become readily apparent upon a review of the following detailed description of the invention, in view of the drawings and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:Figure 1 generally illustrates a wallboard formed by the composition of the present invention in use and also illustrates a spreadable sealant formed by the composition of the present invention; and, Figures 2A and 2B show perspective views of an embodiment of the wallboard shown in Figure 1; Figure 3 generally shows an exemplary formulation of the composition of the present invention; and, Figure 4 generally illustrates a method of forming the wallboard from the composition of the present invention. DETAILED DESCRIPTION

[0028] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.

[0029] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to limit the scope of the claims. As such, those in the art will understand that any suitable material, now known or hereafter developed, may be used in forming the present invention described herein.

[0030] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein or understood to one having skill in the art within, can be used in the practice or testing of the example embodiments.

[0031] The terms “having”, “has”, “including”, “includes” are intended to be substantially synonymous with the terms “comprising” and / or “comprises” and / or “comprise”.

[0032] It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,”“immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “approximately” is intended to mean values within ten percent of the specified value.

[0033] It should be understood that use of “or” in the present application is with respect to a “non-exclusive” arrangement, unless stated otherwise. For example, when saying that “item x is A or B,” it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word “or” is not used to define an “exclusive or” arrangement. For example, an “exclusive or” arrangement for the statement “item x is A or B” would require that x can be only one of A and B. Furthermore, as used herein, “and / or” is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and / or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element.

[0034] Moreover, as used herein, the phrases “comprises at least one of” and “comprising at least one of” in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and, a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element. A similar interpretation is intended when the phrase “used in at least one of:” or “one of:” is used herein.FORMULATION

[0035] The composition of the present invention is composed of calcium carbonate in the range of 10% to 80%. Calcium carbonate is a white powder that is essentially insoluble in water and noncombustible. Calcium carbonate is an inorganic filler which is noncombustible, low cost and reduces shrinkage at high temperature. Calcium carbonate also increases hardness of a polymer composite. Calcium carbonate is often used as a filler or extender in rubbers, plastics or paints and as an opacifying agent in paper. Any form of calcium carbonate may be used, however, light calcium carbonate is preferred for the present composition. Light calcium carbonate particles have regular shapes and are a precipitated form of calcium carbonate. It is a monodisperse powder with small particle size ranging in size from approximately ~3μm down to 30nm with a narrow particle size distribution. Other nonlimiting examples of fillers which may be substituted or used in combination with calcium carbonate include glass fiber which are often used for reinforcing polymers in composites, providing high strength and stiffness. Carbon fibers may also be used which offer excellent strength, stiffness, and low weight, commonly used in aerospace and high- performance applications. Aramid fibers and boron fibers are another lightweight filler known for their high strength-to-weight ratio and impact resistance. Other inorganic fillers may include aluminum oxide particles, silicon carbide particles, mica particles, and hollow glass microspheres which reduce density while providing strength. Sodium tetraborate may also be used which has a low specific gravity of 1.73.

[0036] Fillers to increase strength and reduce materials costs may also be selected from organic materials. These may be lower in weight than inorganic fillers. Potential organic fillers include cellulose fibers such as wood pulp, natural fibers which may include flax, hemp, jute, rice hulls, coconut shell or other natural fiber byproducts. An advantage to using natural fibers is that these raw materials are renewable resources.

[0037] Specific gravity values are presented below for potential fillers used in the present composition. The weight of the final composition can be increased or decreased based on the selection or blend of fillers and the degree of foaming in the end composition material: Filler Specific Gravity (approximation) Gypsum 23g p g while reducing mass of a wallboard configuration of the present composition, may include carbon nanotubes, graphene, nanocellulosic materials, microcapsules, magnesium silicate, montmorillonite, amorphous silica and silica nanoparticles.

[0039] The filler of the present composition may be selected from, or be a combination of: glass fiber, gypsum, calcium carbonate, TiO2or other nonflammable organic or inorganic substances. The filler concentration will range between 10% and 80% of the present composition.

[0040] The composition will also include thermoplastic polymers. Nonlimiting examples of possible thermoplastic polymers that may make up the composition include polyvinyl chloride (PVC), vinyl acetate ethylene (VAE), VAE-acrylic hybrid polymers, vinyl acetate homopolymer, blends of VAE and vinyl acetate homopolymer, blends of VAE and vinyl acetate copolymer, a blend of VAE with polyurethane, a blend of VAE with acrylic copolymer, silane cross-linked VAE achieved by adding silane, acrylic copolymer polyurethane containing polymer, and / or a blend of polyurethane and acrylic, styrene copolymer and polylactic acid. However, it should be appreciated that thermoplastic polymers which are flame retardant or have flame retardant characteristics are preferred, especially when using the present composition for a building material, such as a wallboard. A preferred flame-retardant polymer is PVC, which may be used alone, or in combination with another thermoplastic polymer.

[0041] With respect to possible PVC polymers, one having skill in the art will appreciate PVCs may be classified by their inherent viscosity (IV). Typically, PVC resins for expanded foam havelow inherent viscosity (IV). However, one could increase the PVC concentration by using lower IV resins or lower the PVC concentration by using higher IV (higher molecular weight) PVC resin grades. These variables can affect the physical properties of the PVC, e.g., weight and cost. Examples of low internal viscosity PVC, from the manufacturer K-Bin, include but are not limited to SE450A with an internal viscosity of 0.515, SE650A with an internal viscosity of 0.679, SE650F with an internal viscosity of 0.679, SE750A with an internal viscosity of 0.737, and SE750F with an internal viscosity of 0.737.

[0042] In some embodiments, the total thermoplastic polymer concentration may be between 10% and 80% by weight, and more preferably 20%-40% by weight of the present composition.

[0043] Another aspect of the invention is the use of one or more of a thermosetting polymer, or thermoset. Thermosetting polymers are known for their thermal stability, dimensional integrity, and resistance to heat and chemicals. Thermoset polymers undergo an irreversible chemical crosslinking, forming a three-dimensional network that imparts high mechanical strength and durability in composites derived therefrom. Examples of thermoset polymers include thermally cured acrylate polymers. Acrylate polymers known for their rapid curing and versatile properties, are employed in various applications such as coatings, adhesives, and 3D printing. The polymerization process involves the thermal initiation of acrylate functional groups, resulting in a crosslinked structure.

[0044] Heat stability, in the sense of an end product derived from the present composition, can be controlled in various ways. If the concentration of a particular thermoset is lowered, but the thermoset is selected from acrylate or methacrylate monomers with higher functionality, the end result is tighter crosslinking. A monofunctional acrylate will only react with one neighbor. However, dipropylene glycol diacrylate reacts in two directions to build a linear polymer. In some embodiments, tetra, penta or even hexafunctional acrylate can be used. Thus, for purposes of the present composition, crosslinking generally controls the softness or hardness of the formed composition, i.e., flexibility versus rigidity, whereas mono or di polymers are “longer” and thus are more flexible, and tri or tetra polymers have a tighter weave and thus are more rigid. Dipentaerythritol hexaacrylate is one example of a fast curing and hard acrylate that may be used in the present composition.

[0045] Examples of acrylate monomers and oligomers that may be employed in the present composition include methyl acrylate, ethyl acrylate, tetrahydrofurfuryl acrylate (THFA), 2-phenoxyethyl acrylate (2-PEA), butyl acrylate, 2-ethylhexyl acrylate, isobornyl acrylate, lauryl acrylate, dipropylene glycol diacrylate, stearyl acrylate, hydroxyethyl acrylate (HEA), hydroxypropyl acrylate (HPA), glycidyl acrylate, trimethylolpropane triacrylate (TMPTA), pentaerythritol triacrylate (PETA), pentaerythritol tetraacrylate (PETA-4), diethylene glycol diacrylate (DEGDA), tetraethylene glycol diacrylate (TEGDA), bisphenol A diacrylate (BPA- DA), bisphenol A ethoxylate diacrylate (BPAEDA), 1,6-hexanediol diacrylate (HDDA), polyethylene glycol diacrylate (PEGDA), tris(2-hydroxyethyl) isocyanurate triacrylate (THETA), ethoxylated trimethylolpropane triacrylate (TMPEOTA), isodecyl acrylate, pentaerythritol triacrylate (PETA),and dipentaerythritol hexaacrylate (DPHA).

[0046] In some configurations, methacrylates may also be used as part of the thermoset polymer of the present composition. Non-limiting examples of methacrylates include, isobornyl methacrylate, tridecyl methacrylate, 2-phenoxyethyl methacrylate, ethoxylated (8) Bisphenol A dimethacrylate, bisphenol A dimethacrylate (BPA-DMA), bisphenol A ethoxylate dimethacrylate (BPAEDMA), polyethylene glycol dimethacrylate (PEGDMA), triethylene glycol dimethacrylate (TEGDMA), hexanediol dimethacrylate (HDDMA), isobornyl methacrylate, ethyl methacrylate, butyl methacrylate, lauryl methacrylate, 2-hydroxyethyl methacrylate (HEMA), hydroxypropyl methacrylate (HPMA), glycidyl methacrylate (GMA), trimethylolpropane trimethacrylate (TMPTMA), pentaerythritol tetramethacrylate (PETMA), diethylene glycol dimethacrylate (DEGDMA), tetraethylene glycol dimethacrylate (TEGDMA), bisphenol A dimethacrylate (BPA- DMA), bisphenol A ethoxylate dimethacrylate (BPAEDMA), 1,6-hexanediol dimethacrylate (HDDMA), polyethylene glycol dimethacrylate (PEGDMA), tris(2-hydroxyethyl) isocyanurate trimethacrylate (THETMA), ethoxylated trimethylolpropane trimethacrylate (TMPEOTMA), dipentaerythritol hexaacrylate (DPHA), and isodecyl methacrylate. These acrylates can be sourced commercially from known providers, such as BASF SE, Arkema®, Rahn™, The Dow Chemical Company, Mitsubishi®, and Miwon®. Cyanoacrylates may also be used.

[0047] Other thermosetting polymers may also be useful in the composition. These alternatives may include epoxy resins, which are low cost and known for their adhesion, chemical resistance, and insulation properties. Epoxy chemistry is used in composites as well as coatings, adhesives, and electronic encapsulation. The curing process of an epoxy is typically an exothermic reaction involving an amine or hardener reacting with an epoxy group. Polyurethanes may also be used. Polyurethane thermosets, are generally versatile materials with remarkable flexibility, impactresistance, and excellent adhesion properties, are synthesized by reacting isocyanates with polyols. These polymers find typical applications in foams, elastomers, coatings, and adhesives. Phenolic resins, known for heat resistance, flame retardancy, and mechanical strength, are formed through the reaction of phenol and formaldehyde in the presence of a catalyst. Phenolic resins are low cost and widely used in automotive components, electrical applications, and in composites.

[0048] Other alternatives include polyimides, which generally exhibit outstanding thermal stability, chemical resistance, and mechanical strength, are synthesized by reacting dianhydrides and diamines. Polyimides are commonly used in high-temperature applications, such as aerospace components and electronic devices, thus this alternative may be appropriate for building materials formed from the present composition which are exposed to high-temperatures, e.g., plumping pipes or wallboard in structures in arid / hot climates.

[0049] Further alternatives include melamine formaldehyde resins, which are known to offer excellent heat resistance and dimensional stability, are commonly used in decorative laminates, coatings, and molding compounds due to their durable and scratch-resistant properties. In application, these resins may be desirable for the wallboards formed by the present composition for their known scratch-resistance.

[0050] Still further, alternatives may also include bismaleimide resins. These resins are known to provide exceptional thermal stability and mechanical properties, are suitable for high- temperature applications. The curing process involves the reaction of maleimide groups. These polymers find applications in aerospace components and electronic substrates. Like polyimides, bismaleimide resins may be appropriate for building materials formed from the present composition which may be exposed to high-temperatures, e.g., plumping pipes or wallboard in structures in arid / hot climates.

[0051] Even further, alternatives may further include cyanate ester resins, which are known for having a unique combination of high-temperature performance, low dielectric constant, and low water absorption, are commonly used in electronic and aerospace applications. The curing process involves the cyclotrimerization of cyanate ester groups. The low water absorption characteristics may be appealing for building materials derived from the present composition to be employed in humid climates, or flood zone climates.

[0052] As such, depending on the various building materials the present composition is formed into, selection and substitution of the alternative thermosets, as discussed supra, may be advantageous depending on the particular application of the specific building material.

[0053] In some embodiments, the thermoset polymer concentration of the present composition may be between 1% and 25% by weight, and more preferably 5%-20% by weight of the composition.

[0054] In order for the thermoset to polymerize in the composition it may or may not be necessary to include a radical initiator or initiators. These may include photoinitiators or thermal initiators. It is preferable to use thermal initiators in the present composition but such preference is not to be considered restrictive as to the scope of the appended claims.

[0055] In some arrangements of the present invention, the present composition may also take the form of sealant which sealant is arranged to be compatible with the wallboard. The sealant will adhere to wallboard and seal edges and screws—similar to known-in-the-art joint compound. The sealant composition may be formulated with thermoplastic, thermoset polymers, fillers, thermal initiators, and other additives which are activated with a heat gun.

[0056] Common thermal initiators which can be used to initiate polymerization of the acrylate monomers include dicumyl peroxide. This is a preferred initiator as a residual initiator will act as a flame retardant in the composition. Alternatively, other radical polymerization initiators may be used. Such alternative radical initiators may include, but are not limited to azobisisobutyronitrile (AIBN), benzoin methyl ether (BME), benzoin ethyl ether (BEE), benzoin isobutyl ether (BIE), lauryl peroxide, dibenzoyl peroxide (DBP), tert-butyl peroxybenzoate (TBPB), cumene hydroperoxide, di-tert-butyl peroxide (DTBP), diisopropyl peroxydicarbonate (DIPDC), benzoyl Peroxide (BP), diethyl peroxydicarbonate (DEPDC), tert-butyl peroxyisobutyrate (TBPiB), 2,2'- azobis(2-methylbutyronitrile) (AMBN), and 2,2'-azobis(2,4-dimethylvaleronitrile) (AMV). The choice of initiator can be tuned to the temperature at which it is preferred to manufacture the wallboard or other building material. Another strategy to control the degree of cross-linking, described supra, thus further controlling the potential rigidity or flexibility, is through the choice and concentration of radical initiator. By varying the concentration of dicumyl peroxide, the molecular weight of the crosslinked thermosets can be changed. This is possible because in acrylate chemistry, when low concentrations of radical initiators are used, the polymers grow from a small number of initiator sites and grow until the supply of reactive monomers is exhausted. If ahigh concentration of initiator is used, there are more initiator sites resulting in a larger number of smaller molecular weight. The concentration of initiator in the present invention may range from 0.1% to 5%.

[0057] In some configurations, the present composition may include one or more blowing agents or foaming agents. Foaming agents are typically used in the manufacture of expanded foam products. The desired open or closed cell structure is determined by the formulation, end application, and manufacturing process as well as the choice of foaming agent. Sodium bicarbonate is an endothermic foam agent useful to the invention. Azodicarbonamide (ADC), an exothermic foam agent, is also useful in the invention. Some other chemical foam agents which may be used include dinitrosopentamethylenetetramine (DNPT), a nitrogen releasing foam agent, pentane, butane, isobutane, cyclopentane, hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), and carbon dioxide (CO2).

[0058] Alternatively, physical foaming agents may also be used which do not involve a chemical reaction. These include water, nitrogen, and air.

[0059] Further, biobased foam agents may be used, which biobased foam agents are derived from renewable resources. Two examples which may be used in the present composition include liquified petroleum gas (LPG) derived from biomass, and vegetable oils. Foaming agents in the present composition may in concentrations ranging from 0.5 % to 5%.

[0060] It is also important to include a foaming regulator in the present composition. Foaming regulators are also known as cell regulators or cell stabilizers. They are used to control the size, structure, and distribution of cells in the composite material, i.e., the present composition. Their presence will reduce density of wallboard, thusly resulting in lower total weight. Foaming the composite can also improve insulative properties and noise dampening properties of the building material made from the present composition. One possible example of a foaming regulator is polymethylmethacrylate (PMMA). PMMA is a high molecular weight polymer which stabilizes bubbles and inhibits foam bubble coalescence during composite manufacturing.

[0061] Thus, foaming regulators play a crucial role in achieving the desired physical properties of the foam. While there are various substances that can act as foaming regulators, the specific choice depends on the polymer system and the intended application. Other common foaming regulators include silicone-based compounds, such as silicone oils or silicone surfactants, long chain hydrophobic surfactants, fatty acids, such as stearic acid, and their derivatives. Talc, sodiumbicarbonate and other salts can act as foaming regulators by promoting the nucleation of cells, influencing cell size and distribution. High boiling point alcohols, such as glycols, can influence the foaming process and act as foaming regulators. Foaming regulators may be present in the formulation, i.e., the present composition, in the approximate range of 0.5% to 5%.

[0062] In some arrangements of the present composition, the composition may also include additives, which additives increase the impact resistance of the composite. Chlorinated polyethylene is useful as a toughener and also contributes to fire retardancy. Other additives which can improve impact resistance or toughness include styrene butadiene rubber (SBR), ethylene propylene diene monomer (EPDM), thermoplastic polyurethane (TPU), styrenic block copolymers (SBC), acrylonitrile butadiene rubber (NBR), chloro-sulfonated polyethylene (CSM), liquid butadiene-acrylonitrile rubbers, polybutadiene liquid rubber, core-shell particles, acrylic-based core-shell particles, nanoparticles, butadiene-acrylonitrile core-shell nanoparticles), cross-linked polymers, cross-linked rubber particles, carboxyl-terminated butadiene-acrylonitrile (CTBN), biodegradable polylactic acid (PLA), high-impact polystyrene (HIPS), and silica nanoparticles. Additives for impact resistance and toughness may be present in the present composition ranging from approximately 1% to 5%.

[0063] As discussed supra, 1-hour UL firing rating is a metric of the wallboard derived from the present composition, specifically, a wallboard being less than one-inch and satisfying this rating, thus, fire retardants in the present composition are an important aspect of the invention. Fire retardants are substances incorporated into materials to impede or slow down the progression of fire. The fire retardants can be halogenated or non-halogenated. These compounds function by interfering with the combustion process. Generally, in plastics, fire retardants play an important role in fortifying the fire resistance of polymers. Examples of fire retardants useful in plastic composite formulations include halogenated compounds such as hexabromocyclododecane, tetrabromobisphenol-A, and chlorinated paraffins. Phosphorus-based flame retardants, such as red phosphorus and organophosphates like ammonium polyphosphate, also contribute significantly to fire resistance. Additionally, nitrogen-based compounds like melamine and melamine cyanurate, as well as mineral-based additives including aluminum hydroxide, zinc borate, magnesium hydroxide, and antimony trioxide, further diversify the array of fire retardants available for enhancing the flame resistance of plastic materials. The concentration of flame retardant in the present invention may range from approximately 1% to 10% of the overall composition.Magnesium hydroxide and aluminum hydroxide may function both as a flame retardant and an activator for the thermoset, as discussed supra. Depending on how hot the environment gets (either from extrusion) or from exothermic reactions of blowing agent or radical initiator, the heat may cause magnesium hydroxide to release some water. If this occurs, the water can be harnessed to react with a water sensitive polymer such as cyanoacrylate.

[0064] Additionally, internal and external lubricants are important additives in the wallboard composite and present composition, as the manufacturing process involves extruding boards using a single or twin-screw extruder. Various components can be used to lower melt viscosity and aid in the flow through an extruder by acting as lubricants. These components facilitate the processing of polymer melts, improve melt flow properties, and enhance extrusion efficiency. Various components serve as melt viscosity aids in polymer processing, offering improvements in flow properties and processing efficiency. Processing aids, such as polyethylene wax and polypropylene wax, act as lubricants to reduce melt viscosity, enhancing overall melt flow. Fatty acids and their derivatives, including stearic acid and metallic stearates like zinc stearate and calcium stearate, serve as both lubricants and aids in reducing melt viscosity. Internal lubricants, such as esters (e.g., ester wax) and glycerol esters, reduce friction between polymer chains, lowering melt viscosity. External lubricants, like fatty amides (e.g., stearamide, oleamide) and polyethylene glycol derivatives (PEG), improve processing and reduce melt viscosity. Fluoropolymer additives, such as polytetrafluoroethylene (PTFE), act as lubricants, reducing friction to improve melt flow. Plasticizers, including phthalate plasticizers (e.g., dioctyl Phthalate - DOP) and phosphates, lower melt viscosity and enhance processing in specific polymers. Slip agents, like silicone-based slip agents and ethylene bis(stearamide) (EBS), reduce friction and improve the flow of polymer melts. Solid lubricants, such as graphite and molybdenum disulfide (MoS2), add lubricity to polymer melts and reduce melt viscosity. Surfactants, including fluorosurfactants and nonionic surfactants, may function as lubricants or processing aids. Peroxide-based additives are employed to modify rheological properties and reduce melt viscosity in certain polymers. Metallic compounds, such as Montan Wax, a natural wax containing esters, fatty acids, and hydrocarbons, provide lubrication to polymer melts. Lubricants may compose 0.1% - 5% of the present composition.

[0065] In a preferred embodiment, the present composition includes at least one thermal stabilizers, which are important additives in polymer processing, serving to minimize the degradation of polymers at elevated temperatures. PVC, like other polymers, is susceptible tothermal degradation during its processing. Thus, various thermal stabilizers find application in PVC and other polymer materials to avoid the aforementioned thermal degradation. An example is zinc stearate which generally functions as a thermal stabilizer and as a synergist for foaming agents, while calcium stearate operates together with zinc, eliminating the need for lead compounds. In PVC formulations, several thermal stabilizers are commonly used. Lead-based stabilizers include lead stearate, which acts as a lubricant and thermal stabilizer, and lead phosphite, providing excellent heat stability to PVC. Calcium-zinc stabilizers, represented by calcium-zinc carboxylates, are a combination of calcium and zinc salts functioning as non-toxic thermal stabilizers for PVC. Organotin stabilizers, including methyl tin mercaptides and butyl tin mercaptides, are known for their effectiveness as thermal stabilizers for PVC. Other stabilizers include barium-cadmium stabilizers, organic stabilizers like epoxy-based stabilizers and phosphites.

[0066] Alternatives also include antioxidants, such as phenolic antioxidants like butylated hydroxyanisole (BHA) and butylated hydroxytoluene (BHT), which contribute thermal stability to a wide range of polymers. HALS (hindered amine light stabilizers), exemplified by the Tinuvin® product line, provide excellent thermal and light stability in various polymers. Phosphorus-based stabilizers, including red phosphorus and phosphorus-based flame retardants like ammonium polyphosphate, also are known to contribute to thermal stability. Metal deactivators, where nickel quencher is used in combination with other stabilizers to inhibit metal-catalyzed degradation, are significant and contemplated. Thioethers, represented by thioether antioxidants such as dilauryl thiodipropionate (DLTDP) and distearyl thiodipropionate (DSTDP), are also viable alternatives. Quinones, including peroxide decomposition inhibitors like hydroquinone and benzoquinone are commonly used in plastics. Aromatic amine antioxidants, such as N-phenyl-2-naphthylamine (PAN) and diphenylamine, are also effective in stabilizing polymers against thermal induced degradation. Thermal and light stabilizers may be present in the present invention between approximately 0.1% and 5% of the composite.

[0067] In yet another possible aspect of the invention, colorants including pigment and dyes may be included, which pigments and dyes are used to add color and provide UV protection to the wallboard material. Such UV protection is important for wallboards or other building materials formed from the present composition which may be used in areas exposed to extended direct sunlight. It is worth noting that colorants improve the aesthetics of composite materials, enhancingvisual appeal, thus making build material selection more economical if aesthetic additions are not needed after installation, e.g., colored plumping pipes which may be exposed, wallboards, etc. In the realm of plastics and composites, pigments and dyes are utilized for coloring purposes. The selection of a suitable pigment or dye is contingent upon the specific composite material and the desired properties sought in the end product. For example, Titanium Dioxide (TiO2) is a commonly employed pigment for achieving white color and serving as an inorganic filler in PVC. It also acts as a stabilizer against UV radiation. The use of pigments and dyes aids in achieving a diverse spectrum of colors and visual effects in plastics and composites. Titanium dioxide is a preferred ingredient in the present composition for its filler characteristics and UV stabilization properties.

[0068] For coloring plastics, a range of pigment options is available. Inorganic pigments, such as Iron oxide pigments in red, yellow, brown, and black, are commonly used. Titanium Dioxide serves as a white pigment, contributing to bright and opaque colors. Organic pigments like phthalocyanine pigments (blue, green), quinacridone pigments (red, violet), perylene Pigments (red, yellow, green), and diketopyrrolopyrrole (DPP) Pigments offer vibrant and lightfast colors. Additionally, carbon black provides a deep black color and is prevalent in plastic composites. Metallic pigments, such as aluminum pigments and bronze powder, contribute to metallic effects in coatings and plastics. Mixed metal oxide pigments, known as complex inorganic color pigments (CICP), offer a chemically stable range of colors.

[0069] Dyes can also provide a different avenue for coloring plastics and composites, typically at a reduced cost. Azo dyes, including monoazo and diazo dyes, offer bright shades of yellow, orange, and red. Anthraquinone dyes provide a variety of colors suitable for specific applications. Phthalocyanine dyes in blue and green find applications in textiles, plastics, and composites. Other categories, such as quinoneimine dyes, metal complex dyes, acid dyes, solvent dyes, reactive dyes, disperse dyes, basic dyes, vat dyes, and natural dyes derived from plant-based sources like indigo, turmeric, and madder can be used. Pigments or colorants may be present in a concentration of approximately 0.1% to 10% in the present composition. FIGURES

[0070] Adverting now to the figures, Figure 1 generally illustrates a wallboard 10 formed by the composition of the present invention and also illustrates a spreadable sealant formed by the composition of the present invention, sealant 20. In some embodiments, sealant 20 is activated byheat, as discussed supra., before it may be applied to wallboard 10, as shown in Figure 1, using known methods for applying joint compound and the like.

[0071] Figures 2A and 2B show perspective views of an embodiment of wallboard 10 shown in Figure 1. In some embodiments, wallboard 10 may comprise top end 10b, bottom end 10a, first side 10c and second side 10d. Preferably, wallboard 10 is dimensional and takes a generally rectangular shape, having oppositely disposed planar faces bounded by ends 10a and 10b and sides 10c and 10d. First side 10c includes groove 12 arranged therein and spanning the entirety of side 10c from top end 10b to bottom end 10a. Second side 10d includes protruding portion 14 extending therefrom and spanning the entirety of side 10d from top end 10b to bottom end 10a. Groove 12 and protruding portion 14 can be described as “tongue and groove”, as a respective protruding portion is arranged to be substantially seated within an adjacent groove of a second wallboard, thereby “joining” the wallboards. Once joined, the sealant, shown in Figure 1, may be applied to the seam therebetween.

[0072] Figure 3 generally shows an exemplary formulation of the composition of the present invention. In a preferred formulation of the present composition, the composition comprises: a. Polyvinyl Chloride (PVC) being approximately 25% of the total; b. Tetrahydrofurfuryl acrylate being approximately 9% of the total; c. Dicumyl peroxide being approximately 0.2% of the total; d. Dipropylene glycol diacrylate being approximately 2% of the total; e. Glass fiber being approximately 8% of the total; f. Light calcium carbonate being approximately 47% of the total; g. Sodium bicarbonate being approximately 0.4% of the total; h. Azodicarbonamide being approximately 0.5% of the total; i. Poly (methyl methacrylate) (PMMA) being approximately 1.5% of the total; j. Chlorinated polyethylene (CPE) toughener being approximately 3.3% of the total; k. Lubricant stearic acid being approximately 0.4% of the total; l. Lubricant polyethylene (PE) wax being approximately 0.5% of the total; m. Zinc stearate being approximately 0.8% of the total; n. Calcium stearate being approximately 0.8% of the total; o. TiO2pigment being approximately 0.6% of the total.

[0073] General functionalities pertaining to the aforementioned substances of the present composition are described below.

[0074] PVC: Halogenated thermoplastic which is water resistant. Preferred primary choice and the main resin (or polymer) of the composition.

[0075] Tetrahydrofurfuryl acrylate: First reactive monomer for the thermoset of the composition.

[0076] Dicumyl peroxide: Preferred thermal initiator to polymerize the acrylate thermoset polymer system. Residual initiator will also act as flame retardant.

[0077] Dipropylene glycol diacrylate: Second reactive monomer for the thermoset of the composition and having a higher crosslink density than the first reactive monomer.

[0078] Glass Fiber: Inorganic filler which is lightweight (i.e., reduces overall mass) and noncombustible, thereby adding strength to composite end product.

[0079] Light calcium carbonate: Inorganic filler, noncombustible, low cost and reduces shrinkage at high temperature. Increases hardness of composite end product.

[0080] Sodium bicarbonate: Endothermic foaming agent.

[0081] Azodicarbonamide: Exothermic foaming agent.

[0082] Poly (methyl methacrylate): A high molecular weight polymethylmethacrylate which stabilizes bubbles and inhibits foam bubble coalescence during composite manufacturing / production.

[0083] Chlorinated polyethylene (CPE) toughener: A polymer which increases the impact resistance of the finalized composition. Chlorinated polyethylene used will also add additional fire-retardant properties.

[0084] Stearic acid: Component to lower melt viscosity and aids in flow through extruder by acting as a lubricant.

[0085] Polyethylene (PE) wax: Noncompatible polymer which also aids in flow through extruder acting as an external lubricant.

[0086] Zinc stearate: Thermal stabilizer for PVC, and synergist for foaming agents.

[0087] Calcium stearate: Thermal stabilizer for PVC which works synergistically with zinc, eliminating need for lead compounds in the present composition.

[0088] TiO2Pigment: Pigment for white color and inorganic filler, also provides UV degradation protection.

[0089] Figure 4 generally illustrates an embodiment of a possible method of forming the wallboard from the composition of the present invention. Generally, to produce the present composition and then a building material thereafter, all the selected raw materials or substances, such as those described supra or shown in Figure 3, are weighed appropriately to correspond to their specific percentages. Thereafter, the combination is mixed by at least one of: high-speed mixing; and, low-speed mixing. Once the mixing is completed, the present composition is extruded by an extruder, which could comprise a single or twin-screw extruder, which is then transferred to a mold that will form the selected building material, e.g., the wallboard shown in Figures 1 through 2B. The composition will then cool or be subjected to cooling within the mold to finalize the selected building material, where after, the building material could be subjected to various surface treatments, such as matting or coating. Optionally, the building materials are cut to selected dimensions before shipping.

[0090] It should be noted that the present composition, when extruded with blowing agents exhibits considerably less deformation than the same composition formed by a heat press without blowing agents. Thus, a composite sample (of the present composition) which is extruded and expanded, via blowing agents, will have a lower density and better thermal dimensional stability than a more-dense composite sample produced in a heat press.

[0091] It should be noted that the various embodiments disclosed herein, may be arranged in various combinations according to any of the embodiments shown and described. As such, the embodiments shown and described are merely exemplary and various alternatives, combinations, omissions, of specific components, or foreseeable alternative components, understood by one having ordinary skill in the art, described in the present disclosure or within the field of the present disclosure, are intended to fall within the scope of the appending claims.

[0092] It will be appreciated that various aspects of the invention and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

[0093] LIST OF REFERENCE NUMERALS 10 Wallboard 10a Bottom end 10b Top end 10c First side 10d Second side 12 Groove 14 Protruding Portion 20 Sealant

Claims

CLAIMS What Is Claimed Is:

1. A composition, comprising: a thermoplastic comprising approximately 25% of the composition, the thermoplastic being polyvinyl chloride; a thermoset comprising approximately 11.2% of the composition, the thermoset including: tetrahydrofurfuryl acrylate (THFA), dicumyl peroxide (DCP), and dipropylene glycol diacrylate (DPGDA); an inorganic filler comprising approximately 55.6% of the composition, the inorganic filler including: glass fiber, light calcium carbonate, and TiO2pigment; and, approximately 8.2% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

2. A use of the composition recited in Claim 1 in a wallboard.

3. A use of the composition recited in Claim 1 for plumping pipe.

4. A use of the composition recited in Claim 1 for a spreadable sealant.

5. The composition recited in Claim 1, wherein the 8.2% of the composition includes: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

6. The composition recited in Claim 5, wherein: the at least one foaming agent comprising sodium bicarbonate and azodicarbonamide; the foaming regulator comprises poly (methyl methacrylate); the fire retardant comprises chlorinated polyethylene; the at least one lubricant comprising stearic acid and polyethylene wax; and, the at least one thermal stabilizer comprising zinc stearate and calcium stearate.

7. The composition recited in Claim 6, wherein: the sodium bicarbonate and azodicarbonamide comprise approximately 0.9% of the composition; the poly (methyl methacrylate) comprises approximately 1.5% of the composition; the chlorinated polyethylene comprises approximately 3.3% of the composition; the stearic acid and polyethylene wax comprise approximately 0.9% of the composition; and, the zinc stearate and calcium stearate comprise approximately 1.6% of the composition.

8. The composition recited in Claim 1, wherein the light calcium carbonate comprises approximately 47% of the composition.

9. The composition recited in Claim 1, wherein the glass fiber comprises approximately 8% of the composition.

10. The composition recited in Claim 1, wherein the TiO2pigment comprises approximately 0.6% of the composition.

11. A composition comprising: a thermoplastic comprising approximately 20 to 40% of the composition; a thermoset comprising approximately 5 to 20% of the composition; a filler comprising approximately 10 to 80% of the composition, the filler including at least one of: a nonflammable inorganic; and a nonflammable organic; and, approximately 2.2 to 30% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

12. A wallboard made from the composition recited in Claim 11.

13. The composition recited in Claim 11, wherein the thermoplastic comprises polyvinyl chloride.

14. The composition recited in Claim 13, wherein the filler comprises at least one of: glass fiber, light calcium carbonate, and TiO2pigment.

15. The composition recited in Claim 14, wherein the thermoset includes at least one of: tetrahydrofurfuryl acrylate (THFA); dicumyl peroxide (DCP); and, dipropylene glycol diacrylate (DPGDA).

16. The composition recited in Claim 15 further comprises at least one additive comprising approximately 1 to 5% of the composition.

17. A wallboard made from the composition recited in Claim 15.

18. The wallboard recited in Claim 17 further comprising: a top end; a bottom end; a first side end having a groove arranged therein and spanning the first side from top end and the bottom end; and, a second side arranged opposite the first side, the second side having a protruding portion extending therefrom and spanning the second side from the top end to the bottom end.

19. The composition recited in Claim 13, wherein the thermoset comprising at least one of an acrylate and methacrylate.

20. The composition recited in Claim 11, wherein: said thermoplastic is polyvinyl chloride and comprises approximately 25% of the composition; said thermoset including: tetrahydrofurfuryl acrylate (THFA), dicumyl peroxide (DCP), and dipropylene glycol diacrylate (DPGDA), said thermoset comprising approximately 11.2% of the composition; and, said filler including: glass fiber, light calcium carbonate, and TiO2pigment, said filler comprising approximately 55.6% of the composition.

21. The composition recited in Claim 20 comprising approximately 8.2% of: said at least one foaming agent; said foaming regulator; said fire retardant; said at least one lubricant; and, said at least one thermal stabilizer.

22. A wallboard comprised of a composition, the composition comprising: polyvinyl chloride comprising approximately 20 to 40% of the composition; a thermoset comprising at least one of an acrylate and methacrylate, said thermoset comprising approximately 5 to 20% of the composition; a filler comprising approximately 10 to 80% of the composition, the filler including at least one of: a nonflammable inorganic; and a nonflammable organic; and, approximately 2.2 to 30% of the composition including at least one of: at least one foaming agent; a foaming regulator; a fire retardant; at least one lubricant; and, at least one thermal stabilizer.

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