Low dust wall repair compound

Abstract

A wall repair compound useful for filling and repairing cracks, holes, and other imperfections in a wall surface includes a conventional filler material, a conventional binder material, and a dust reducing additive which reduces the quantity of airborne dust particles generated when sanding the hardened joint compound. Airborne dust reducing additives include oils, surfactants, solvents, waxes, and other petroleum derivatives. The additive can be added to conventional ready-mixed joint compounds and to setting type joint compounds. A method of reducing the quantity of airborne dust generated when sanding a fully hardened joint compound includes mixing a sufficient quantity of the dust reducing additive with the joint compound prior to when the joint compound has been applied to the wall.

1 . A method of using a joint compound, the method comprising 
 a. applying a joint compound composition to a joint between adjacent wallboard panels, the joint compound composition comprising 
 i) binder,  
 ii) filler,  
 iii) wax, and  
 iv) water,  
 and exhibiting a mud-like consistency;  
   b. allowing the composition to dry; and    c. sanding the dried composition.    
   
   
       2 . The method of  claim 1 , wherein the wax comprises a polymeric wax.  
   
   
       3 . The method of  claim 1 , wherein the wax comprises a synthetic polymer wax.  
   
   
       4 . The method of  claim 1 , wherein the wax comprises paraffin wax.  
   
   
       5 . The method of  claim 1 , wherein the wax is soluble in water.  
   
   
       6 . The method of  claim 1 , wherein the joint compound composition comprises from about 1.5% by weight to about 6% by weight wax.  
   
   
       7 . The method of  claim 6 , wherein the wax comprises at least one of natural wax, synthetic polymer wax, and paraffin wax.  
   
   
       8 . The method of  claim 1 , wherein the wax is miscible in water.  
   
   
       9 . The method of  claim 1 , wherein the wax has a melting temperature from about 38° C. to about 41° C.  
   
   
       10 . The method of  claim 1 , wherein the filler is selected from the group consisting of calcium carbonate, calcium sulfate dehydrate, and calcium sulfate hemihydrate.  
   
   
       11 . The method of  claim 1 , wherein the binder is selected from the group consisting of acrylic resins, vinyl acetate copolymers and combinations thereof.  
   
   
       12 . The method of  claim 1 , wherein the binder comprises at least one of polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate copolymer, styrenebutadiene, and polyacrylamide.  
   
   
       13 . The method of  claim 1 , wherein the joint compound composition comprises from about 55% by weight to about 75% by weight filler.  
   
   
       14 . The method of  claim 6 , wherein the joint compound composition comprises from about 55% by weight to about 75% by weight filler.  
   
   
       15 . The method of  claim 1 , wherein the joint compound composition further comprises thickener.  
   
   
       16 . The method of  claim 15 , wherein the thickener comprises at least one of methyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl hydroxypropyl cellulose, ethyl hydroxyethyl cellulose and sodium carboxymethyl cellulose.  
   
   
       17 . The method of  claim 1 , wherein the joint compound composition further comprises at least one of clay, attapulgus clay, bentonite, illite, kaolin, and sepiolite.  
   
   
       18 . The method of  claim 1 , wherein the joint compound composition further comprises starch.  
   
   
       19 . The method of  claim 1 , wherein the joint compound composition further comprises glass bubbles.  
   
   
       20 . The method of  claim 1 , wherein the filler comprises at least one of mica, perlite, talc, limestone, pyrophyllite, silica and diatomaceous earth.